Patent Abstract:
A secondary battery including an electrode assembly, a can including a bottom plate and a sidewall extending from the bottom plate, the can being configured to accommodate the electrode assembly, and an insulating case including a plate-shaped main body facing the electrode assembly and a support part extending from the main body, the insulating case being accommodated in the can, wherein the support part of the insulating case includes at least one support wall bent from the main body.

Full Description:
This application claims the benefit under 35 USC 119(a-d) of Korean Patent Application No. 10-2009-0058361, filed on Jun. 29, 2009, the contents incorporated by reference herein in its entirety. 
     BACKGROUND 
     1. Field 
     Embodiments relate to a secondary battery. 
     2. Description of the Related Art 
     Recently, the use of portable electronic devices has increased with the rapid development of communication and computer industries. Rechargeable secondary batteries are widely used as power sources of portable electronic devices. 
     In a secondary battery, an electrode assembly may be accommodated in an outer case. Secondary batteries may be classified into, e.g., pouch and can types, according to their outer cases. Can type secondary batteries may be further classified into, e.g., cylinder and prismatic types, according to the shape of the cans. Generally, a prismatic secondary battery includes an electrode assembly, a prismatic can housing the electrode assembly, a cap assembly configured to close an opening of the can, and an insulating case disposed in the can to insulate the electrode assembly and the cap assembly. 
     SUMMARY 
     Embodiments are directed to a secondary battery, which represent advances over the related art. 
     It is a feature of an embodiment to provide a secondary battery that may be easily fabricated at lower cost. 
     At least one of the above and other features and advantages may be realized by providing a secondary battery including an electrode assembly, a can including a bottom plate and a sidewall extending from the bottom plate, the can being configured to accommodate the electrode assembly, and an insulating case including a plate-shaped main body facing the electrode assembly and a support part extending from the main body, the insulating case being accommodated in the can, wherein the support part of the insulating case includes at least one support wall bent from the main body. 
     The insulating case may include a bending groove between the main body and the support wall. 
     The support part may include a plurality of support walls separated from each other. 
     The main body of the insulating case may have a rectangular shape with two mutually facing long sides and two mutually facing short sides, and the support walls may be disposed on the two mutually facing long sides of the main body. 
     The main body of the insulating case may have a rectangular shape with two mutually facing long sides and two mutually facing short sides, and the support walls may be disposed on the two mutually facing short sides of the main body. 
     The main body of the insulating case may have a rectangular shape with two mutually facing long sides and two mutually facing short sides, and the support walls may be disposed on long and short sides of the main body. 
     The support walls may have lengths that are the same as lengths of corresponding sides of the main body. 
     The support walls disposed on the two mutually facing long sides of the main body may be shorter in length than the two mutually facing long sides of the main body. 
     Each of the support walls may form an angle of about 75° to about 105° with respect to the main body. 
     The support part may further include at least one support wall not bent from the main body. 
     The can may further include a separation prevention part configured to prevent detachment of the insulating case. 
     The separation prevention part may include a stopper contacting an upper end of at least one of the support walls. 
     The separation prevention part may include a plurality of the stoppers, the support part may include a plurality of the support walls, and the stoppers may correspond to the support walls. 
     An inwardly bent extension extending from an upper end of the sidewall of the can may form the stopper. 
     The separation prevention part may include a catch groove in the sidewall of the can. 
     The support wall of the insulating case may include a latch part for insertion into the catch groove. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above and other features and advantages will become more apparent to those of ordinary skill in the art by describing in detail exemplary embodiments with reference to the attached drawings, in which: 
         FIG. 1  illustrates a perspective view of a secondary battery according to an embodiment; 
         FIG. 2A  illustrates a cross-sectional view taken along line A-A of  FIG. 1 ; 
         FIG. 2B  illustrates a cross-sectional view taken along line B-B of  FIG. 1 ; 
         FIG. 3  illustrates an exploded perspective view of the secondary battery of  FIG. 1 ; 
         FIG. 4A  illustrates a cross sectional view of an insulating case of  FIG. 3 , taken along line C-C; 
         FIG. 4B  illustrates a cross sectional view of the insulating case of  FIG. 3 , taken along line D-D; 
         FIG. 5  illustrates a perspective view of an insulating case included in a secondary battery according to another embodiment; 
         FIG. 6  illustrates a perspective view of an insulating case included in a secondary battery according to yet another embodiment; 
         FIG. 7  illustrates a perspective view of an insulating case included in a secondary battery according to a further embodiment; 
         FIG. 8  illustrates a perspective view of an insulating case included in a secondary battery according to a still further embodiment; and 
         FIG. 9  illustrates a partial sectional view of a secondary battery according to yet another embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     Example embodiments will now be described more fully hereinafter with reference to the accompanying drawings; however, they may be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. 
     In the drawing figures, the dimensions of layers and regions may be exaggerated for clarity of illustration. It will also be understood that when a layer or element is referred to as being “on” another layer or substrate, it can be directly on the other layer or substrate, or intervening layers may also be present. Further, it will be understood that when a layer is referred to as being “under” another layer, it can be directly under, and one or more intervening layers may also be present. In addition, it will also be understood that when a layer is referred to as being “between” two layers, it can be the only layer between the two layers, or one or more intervening layers may also be present. Like reference numerals refer to like elements throughout. 
     First, a secondary battery according to an embodiment will be described.  FIGS. 1 to 4B  illustrate a secondary battery according to an embodiment.  FIG. 1  illustrates a perspective view of the secondary battery.  FIGS. 2A and 2B  illustrate cross-sectional views taken along lines A-A and B-B of  FIG. 1 .  FIG. 3  illustrates an exploded perspective view of the secondary battery of  FIG. 1 .  FIGS. 4A and 4B  illustrate cross-sectional views of an insulating case of  FIG. 3 , taken along lines C-C and D-D. 
     Referring to  FIGS. 1 to 3 , a secondary battery  100  may include an electrode assembly  110 , a can  120 , an insulating case  130 , and a cap assembly  140 . The secondary battery  100  may store electrical energy supplied from a battery charger (not shown) and may supply the stored electric energy to an external load (not shown). 
     The electrode assembly  110  may include a first electrode plate  111 , a second electrode plate  112 , and a separator  113  between the first and second electrode plates  111  and  112 . The first electrode plate  111 , the second electrode plate  112 , and the separator  113  may be wound in the form of a jelly roll. A first electrode tab  111   a  may be coupled to the first electrode plate  111  and may protrude from a top side of the electrode assembly  110 . A second electrode tab  112   a  may be coupled to the second electrode plate  112  and may protrude from the top side of the electrode assembly  110 . The first electrode plate  111  may be a negative electrode plate and the second electrode plate  112  may be a positive electrode plate. Thus, the first electrode tab  111   a  may be a negative electrode tab and the second electrode tab  112   a  may be a positive electrode tab. However, the embodiments are not limited thereto. Alternatively, the first electrode plate  111  may be a positive electrode plate and the second electrode plate  112  may be a negative electrode plate. In this case, the first electrode tab  111   a  may be a positive electrode tab and the second electrode tab  112   a  may be a negative electrode tab. 
     The can  120  may include a bottom plate  121 , a sidewall  122 , and a separation prevention part  128 . The electrode assembly  110  and the insulating case  130  may be accommodated in the can  120 . The can  120  may be formed of a metal, e.g., light and ductile aluminum or an aluminum alloy. However, materials that may be used for forming the can  120  are not limited thereto. The bottom plate  121  may have an elongated rectangular shape. 
     The sidewall  122  may be approximately perpendicular to the bottom plate  121  and may be connected to edges of the bottom plate  121 . The sidewall  122  may include mutually facing long walls  123   a  and  123   b , and mutually facing short walls  124   a  and  124   b . A rectangular opening  122   a  may be formed at an end part  122   b  of the sidewall  122  as an opening for inserting the electrode assembly  110  and the insulating case  130  into the can  122 . The opening  122   a  may be sealed by the cap assembly  140 . 
     The separation prevention part  128  may include a plurality of stoppers  129   a ,  129   b ,  129   c , and  129   d . The insulating case  130  may not be separated from the can  120  due to, e.g., the presence of the separation part  128 . 
     The stoppers  129   a ,  129   b ,  129   c , and  129   d  may extend from an end part  122   b  of the sidewall  122  toward a center of the opening  122   a . The stoppers  129   a ,  129   b ,  129   c , and  129   d  may be disposed on respective long walls  123   a  and  123   b  and short walls  124   a  and  124   b . As illustrated by dashed lines in  FIG. 3 , extensions  1291   a ,  1291   b ,  1291   c , and  1291   d  may extend from the end part  122   b  of the sidewall  122  in parallel with the sidewall  122 . The stoppers  129   a ,  129   b ,  129   c , and  129   d  may be formed by bending the extensions  1291   a ,  1291   b ,  1291   c , and  1291   d  toward the opening  122   a . That is, after the electrode assembly  110  and the insulating case  130  are inserted into the can  120  through the opening  122   a , the stoppers  129   a ,  129   b ,  129   c , and  129   d  may be formed by bending the extensions  1291   a ,  1291   b ,  1291   c , and  1291   d.    
     The insulating case  130  may include a main body  131  and a support part  136 . When assembled, the insulating case  130  may be accommodated in the can  120  between the electrode assembly  110  and the cap assembly  140 . The insulating case  130  may provide insulation between the electrode assembly  110  and the cap assembly  140 . The can  120  may prevent the electrode assembly  110  from moving inside the can  120 . The insulating case  130  may be formed of an insulating material, e.g., polypropylene (PP). 
     The main body  131  may have a plate shape corresponding to the shape of the opening  122   a . The main body  131  may include a first electrode tab hole  132 , a second electrode tab hole  133 , and an electrolyte introduction hole  134 . The main body  131  may face the electrode assembly  110  and may provide electric insulation between the electrode assembly  110  and the cap assembly  140 . When assembled, the first electrode tab  111   a  of the electrode assembly  110  may be inserted through the first electrode tab hole  132 . The second electrode tab  112   a  of the electrode assembly  110  may be inserted through the second electrode tab hole  133 . Electrolyte may be introduced into the electrode assembly  110  through the electrolyte introduction hole  134 . 
     The support part  136  may include a plurality of bent support walls  137   a ,  137   b ,  137   c , and  137   d . The support part  136  may contact the sidewall  122  of the can  120  and may support the main body  131 . Thus, the electrode assembly  110  may be held in the can  120  without movement thereto relative to the can  120 . 
     The support walls  137   a ,  137   b ,  137   c , and  137   d  may be approximately perpendicular to the main body  131  and may be coupled to edges of the main body  131 . The support walls  137   a ,  137   b ,  137   c , and  137   d  may be disposed on corresponding sides of the main body  131 . Each of the support walls  137   a ,  137   b ,  137   c , and  137   d  may have a length that is the same as a length of the corresponding side of the main body  131 . The support walls  137   a ,  137   b ,  137   c , and  137   d  may have the same height as one another. Ends  1371   a ,  1371   b ,  1371   c , and  1371   d  of the support walls  137   a ,  137   b ,  137   c , and  137   d  may abut against the stoppers  129   a ,  129   b ,  129   c , and  129   d  of the can  120 , respectively. Therefore, the insulating case  130  may not disengage from inside of the can  120 . 
     As illustrated by dashed lines in  FIG. 3 , extension wings  138   a ,  138   b ,  138   c , and  138   d  may extend from four sides of the main body  131  to be coplanar with the main body  131 . The support walls  137   a ,  137   b ,  137   c , and  137   d  may be formed by bending the extension wings  138   a ,  138   b ,  138   c , and  138   d  until the extension wings  138   a ,  138   b ,  138   c , and  138   d  become approximately perpendicular to the main body  131 . Bending grooves  139  may be disposed between the support walls  137   a ,  137   b ,  137   c , and  137   d  and the main body  131  ( FIGS. 4A and 4B ). Since the thickness of the main body  131  may be reduced at the bending grooves  139 , the extension wings  138   a ,  138   b ,  138   c , and  138   d  may be easily bent to form the support walls  137   a ,  137   b ,  137   c , and  137   d.    
     An angle (a) between the support walls  137   a ,  137   b ,  137   c , and  137   d  and the main body  131  may be 90°±15°, i.e., about 75° to about 105°. Maintaining the angle at about 75° to about 105° may help ensure that the ends  1371   a ,  1371   b ,  1371   c , and  1371   d  of the support walls  137   a ,  137   b ,  137   c , and  137   d  are easily located adjacent to the stoppers  129   a ,  129   b ,  129   c , and  129   d.    
     The cap assembly  140  may include a cap plate  141 , an insulating plate  142 , a terminal plate  143 , and an electrode terminal  144 . The cap assembly  140  may close the opening  122   a  of the can  120 . Two terminals of the secondary battery  100  may be disposed on the cap assembly  140 . 
     The cap plate  141  may include a terminal hole  141   a  and an electrolyte injection hole  141   b . The cap plate  141  may be, e.g., a rectangular metal plate having a size and shape corresponding to the size and shape of the opening  122   a  of the can  120 . The cap plate  141  may be placed on the end part  122   b  of the sidewall  122  and the stoppers  129   a ,  129   b ,  129   c , and  129   d  of the can  120  and may be coupled to the can  120  by, e.g., laser welding, so as to close the opening  122   a  of the can  120 . The second electrode tab  112   a  of the electrode assembly  110  may be coupled to the cap plate  141  by, e.g., laser welding, so that the cap plate  141  may function as a second terminal of the secondary battery  100 . 
     The terminal hole  141   a  may be disposed in a center part of the cap plate  141 . When assembled, the electrode terminal  144  may be inserted through the terminal hole  141   a.    
     The electrolyte injection hole  141   b  may be disposed at a side of the terminal hole  141   a . Electrolyte may be supplied into the can  120  through the electrolyte injection hole  141   b . After electrode is supplied, the electrolyte injection hole  141   b  may be closed using a plug  141   c.    
     A first passage hole  142   a  may be disposed in a side of the insulating plate  142 . The electrode terminal  144  may be inserted through the first passage hole  142   a . The insulating plate  142  may contact an inner surface of the cap plate  141  (facing the electrode assembly  110 ) and may provide electric insulation between the terminal plate  143  and the cap plate  141 . 
     The terminal plate  143  may contact the insulating plate  142  and may be electrically insulated from the cap plate  141  by the insulating plate  142 . That is, since the insulating plate  142  may be disposed between the terminal plate  143  and the cap plate  141 , the terminal plate  143  and the cap plate  141  may be electrically insulated from each other. The first electrode tab  111   a  of the electrode assembly  110  may be coupled to the terminal plate  143  by, e.g., laser welding. A second passage hole  143   a  may be disposed in a side of the terminal plate  143 . The electrode terminal  144  may be inserted through the second passage hole  143   a . The terminal plate  143  may be formed of, e.g., nickel, but is not limited thereto. 
     The electrode terminal  144  may be inserted through the terminal hole  141   a  of the cap plate  141  and may be coupled to the terminal plate  143 . The electrode terminal  144  may be electrically connected to the first electrode tab  111   a  and electrically insulated from the cap plate  141  by a gasket  148 , so that the electrode terminal  144  may function as a first terminal of the secondary battery  100 . 
     Next, a secondary battery according to another embodiment will be described.  FIG. 5  illustrates a perspective view of an insulating case included in a secondary battery according to another embodiment. In the current embodiment, the same elements as those of the previous embodiment will be denoted with the same reference numerals. 
     Referring to  FIG. 5 , an insulating case  230  may include a main body  131  and a support part  236 . The insulating case  230  may have the same structure as that of the insulating case  130  of the previous embodiment except for the support part  236 . Thus, only the support part  236  will be described in detail below. 
     The support part  236  may include a plurality of support walls  237   a ,  237   b ,  237   c , and  237   d . Each of the support walls  237   a ,  237   b ,  237   c , and  237   d  may be approximately perpendicular to the main body  131  and may be connected to an edge of the main body  131 . The support walls  237   a ,  237   b ,  237   c , and  237   d  may be coupled to respective sides of the rectangular main body  131 . Each of the support walls  237   a ,  237   b ,  237   c , and  237   d  may have a length shorter than a length of its corresponding side of the main body  131 . The support walls  137   a ,  137   b ,  137   c , and  137   d  may have the same height as one another. 
     As illustrated by dashed lines in  FIG. 5 , extension wings  238   a ,  238   b ,  238   c , and  238   d  may extend from the main body  131  in the same plane as the main body  131 . Support walls  237   a ,  237   b ,  237   c , and  237   d  may be formed by bending the extension wings  238   a ,  238   b ,  238   c , and  238   d  until the extension wings  238   a ,  238   b ,  238   c , and  238   d  become approximately perpendicular to the main body  131 . Bending grooves (not illustrated) may be disposed between the main body  131  and the extension wings  238   a ,  238   b ,  238   c , and  238   d.    
     In the insulating case  230  of the current embodiment, the length of the support walls  237   a ,  237   b ,  237   c , and  237   d  may be shorter than the length of the corresponding sides of the main body  131 . That is, the insulating case  230  may have bent parts that are smaller than those in the insulating case  130  of the previous embodiment. Therefore, the insulating case  230  may be less susceptible to damage at the bent parts. 
     Stoppers (not shown) of a can (not shown) may be formed according to the support walls  237   a ,  237   b ,  237   c , and  237   d  to prevent separation of the insulating case  230  from the can. 
     Next, a secondary battery according to another embodiment will be described.  FIG. 6  illustrates a perspective view of an insulating case included in a secondary battery according to another embodiment. In the current embodiment, the same elements as those of the embodiment illustrated in  FIGS. 1 to 4B  will be denoted with the same reference numerals. 
     Referring to  FIG. 6 , an insulating case  330  may include a main body  131  and a support part  336 . The insulating case  330  may have the same structure as that of the insulating case  130  of the embodiment illustrated in  FIGS. 1 to 4B  except for the support part  336 . Thus, only the support part  336  will be described in detail below. 
     The support part  336  may include two support walls  337   a  and  337   b . Each of the support walls  337   a  and  337   b  may be approximately perpendicular to the main body  131 . The two support walls  337   a  and  337   b  may be disposed on respective short sides of the rectangular main body  131 . Each of the support walls  337   a  and  337   b  may have a length the same as a length of the corresponding side of the main body  131 . The support walls  337   a  and  337   b  may have the same height as one another. 
     As illustrated by dashed lines in  FIG. 6 , extension wings  338   a  and  338   b  may extend from the main body  131  to be coplanar with the main body  131 . The two support walls  337   a  and  337   b  may be formed by bending the extension wings  338   a  and  338   b  until the extension wings  338   a  and  338   b  become approximately perpendicular to the main body  131 . Bending grooves (not illustrated) may be disposed between the main body  131  and the extension wings  338   a  and  338   b.    
     In the insulating case  330  of the current embodiment, the two support walls  337   a  and  337   b  may be disposed at respective short sides of the main body  131 . Therefore, the insulating case  330  may be easily manufactured. That is, the main body  131  and the extension wings  338   a  and  338   b  may have a simple rectangular shape. 
     Stoppers (not shown) of a can (not shown) may be formed corresponding to the support walls  337   a  and  337   b  to prevent separation of the insulating case  330  from the can. 
     Next, a secondary battery according to another embodiment will be described.  FIG. 7  illustrates a perspective view of an insulating case included in a secondary battery according to another embodiment. In the current embodiment, the same elements as those of the embodiment illustrated in  FIGS. 1 to 4B  are denoted with the same reference numerals. 
     Referring to  FIG. 7 , an insulating case  430  may include a main body  131  and a support part  436 . The insulating case  430  may have the same structure as that of the insulating case  130  of the embodiment illustrated in  FIGS. 1 to 4B  except for the support part  436 . Thus, only the support part  436  will be described in detail below. 
     The support part  436  may include two support walls  437   a  and  437   b . Each of the two support walls  437   a  and  437   b  may be approximately perpendicular to the main body  131 . The two support walls  437   a  and  437   b  may be disposed on respective long sides of the rectangular main body  131 . Each of the support walls  437   a  and  437   b  may have a length the same as a length of the corresponding side of the main body  131 . The support walls  437   a  and  437   b  may have the same height as one another. 
     As illustrated by dashed lines in  FIG. 7 , extension wings  438   a  and  438   b  may extend from the main body  131  to be coplanar with the main body  131 . The two support walls  437   a  and  437   b  may be formed by bending the extension wings  438   a  and  438   b  until the extension wings  438   a  and  438   b  become approximately perpendicular to the main body  131 . Bending grooves (not illustrated) may be disposed between the main body  131  and the extension wings  438   a  and  438   b.    
     In the insulating case  430  of the current embodiment, the two support walls  437   a  and  437   b  may be disposed on respective long sides of the main body  131 . Therefore, the insulating case  430  may be easily manufactured. That is, the main body  131  and the extension wings  438   a  and  438   b  may have a simple rectangular shape. 
     Stoppers (not shown) of a can (not shown) may be formed corresponding to the support walls  437   a  and  437   b  to prevent separation of the insulating case  430  from the can. 
     Next, a secondary battery according to another embodiment will be described.  FIG. 8  illustrates a perspective view of an insulating case included in a secondary battery according to another embodiment. In the current embodiment, the same elements as those of the embodiment illustrated in  FIGS. 1 to 4B  are denoted with the same reference numerals. 
     Referring to  FIG. 8 , an insulating case  530  may include a main body  131  and four support walls  537   a ,  537   b ,  537   c , and  537   d . The main body  131  of the current embodiment may have the same structure as that of the main body  131  of the embodiment illustrated in  FIGS. 1 to 4B , and thus a repeated detailed description of the main body  131  is omitted. 
     Three support walls  527   a ,  537   c , and  537   d  of the four support walls  537   a ,  537   b ,  537   c , and  537   d  may be connected to each other in one piece. That is, the three support walls  527   a ,  537   c , and  537   d  may not be formed by bending parts of the main body  131 . In other words, the support walls  527   a ,  537   c , and  537   d  may be connected to each other at edges thereof. The remaining support wall  537   b  of the four support walls  537   a ,  537   b ,  537   c , and  537   d  may be formed by bending a part of the main body  131 . In the current embodiment, only one support wall may be formed by bending an extension wing  538   b  of the main body  131 . However, the embodiments are not limited thereto. For example, two or three support walls may be formed by bending extension wings of the main body  131 . 
     Next, a secondary battery according to another embodiment will be described.  FIG. 9  illustrates a partial sectional view of a secondary battery according to another embodiment. In the current embodiment, the same elements as those of the embodiment illustrated in  FIGS. 1 to 4B  are denoted with the same reference numerals. 
     Referring to  FIG. 9 , a secondary battery  600  may include a can  620  and an insulating case  630  accommodated in the can  620 . The secondary battery  600  of the current embodiment may have the same structure as that of the secondary battery  100  of the embodiment illustrated in  FIGS. 1 to 4B  except for the can  620  and the insulating case  630 . Therefore, only the can  620  and the insulating case  630  will be described in detail for brevity of description. 
     The can  620  may include a bottom plate  121  and a sidewall  622  extending upward from edges of the bottom plate  121 . Catch grooves  622   a  may be disposed in an upper, inner surface of the sidewall  622 . 
     The insulating case  630  may include a main body  631  and support walls  637   b  and  637   d  that are bent from the main body  631 . Latch parts  637   b   1  and  637   b   2  may be disposed at ends of the support walls  637   b  and  637   d  for insertion into the catch grooves  622   a  of the can  620 . The latch parts  637   b   1  and  637   d   1  may have a length corresponding to a length of the catch grooves  622   a . The latch parts  637   b   1  and  637   d   1  may have an outwardly protruded shape. 
     According to the embodiments, a secondary battery that may be easily fabricated at lower cost is provided. That is, since the support walls of the insulating case may be formed by bending, the secondary battery may be easily fabricated at lower cost. 
     Exemplary embodiments have been disclosed herein, and although specific terms are employed, they are used and are to be interpreted in a generic and descriptive sense only and not for purpose of limitation. Accordingly, it will be understood by those of ordinary skill in the art that various changes in form and details may be made without departing from the spirit and scope of the present invention as set forth in the following claims.

Technology Classification (CPC): 7