Patent Description:
A secondary battery is a power storage system that provides excellent energy density to change electrical energy into chemical energy so as to store the chemical energy. In contrast to non-rechargeable primary batteries, secondary batteries are generally rechargeable and may be used for a variety of electronic devices such as smartphones, cellular phones, laptops, tablet PCs, and the like. Recently, interests in electric vehicles have increased to prevent or reduce environmental pollution, and thus, high-capacity secondary batteries are being adopted for the electric vehicles. Such secondary batteries may desirably have characteristics such as high density, high output, and stability. Secondary batteries known from prior art are disclosed in the documents <CIT> and <CIT>.

Aspects of some embodiments of the present disclosure include a secondary battery in which insulating performance and a shape of an electrode assembly are maintained through components of one insulator.

The characteristics of embodiments according to the present disclosure are not limited to the above-mentioned characteristics, and other characteristics not mentioned herein will be clearly understood by those skilled in the art from this specification and the attached drawings.

According to some embodiments, a secondary battery includes: an electrode assembly comprising a first electrode plate, a second electrode plate, and a separator between the first electrode plate and the second electrode plate; a case configured to accommodate the electrode assembly; a cap assembly electrically connected to the second electrode plate of the electrode assembly; and an insulator coupled to an upper side of the electrode assembly, wherein the insulator includes: an insulating upper portion configured to cover the upper side of the electrode assembly; an insulating side portion between the case and a side portion of the electrode assembly; and an insulating core portion inserted into a hollow portion of the electrode assembly to support the electrode assembly.

According to some embodiments, the insulating core portion may have a length greater than that of the insulating side portion.

According to some embodiments, the length of the insulating core portion may be about <NUM>% to about <NUM>%, preferably about <NUM>% to about <NUM>%, of a length of the electrode assembly.

According to some embodiments, a diameter of a lower end of the insulating core portion may be less than that of the other area of the insulating core portion.

According to some embodiments, the insulating core portion may be inclined with respect to a direction in which the electrode assembly extends.

According to some embodiments, a thickness of a lower end of the insulating core portion may be less than that of the other area of the insulating core portion.

According to some embodiments, each of the insulating side portion, the insulating upper portion, and the insulating core portion may have a thickness of about <NUM> to about <NUM>, preferably of about <NUM> to about <NUM>.

According to some embodiments, the insulator may further include a first hole passing between top and bottom surfaces of a center of the insulating core portion.

According to some embodiments, an end of the insulating side portion facing the electrode assembly may be chamfered.

According to some embodiments, the insulator may further include an insulating rib that may be configured to connect the insulating upper portion to the insulating core portion.

According to some embodiments, the insulating rib may have a circular plate shape that may connect an outer edge of the insulating core portion to an inner edge of the insulating upper portion.

According to some embodiments, the insulating rib may further include at least one second hole passing between top and bottom surfaces thereof.

According to some embodiments, the insulating rib may be provided in plurality, which may be spaced apart from and symmetrical to each other with respect to the insulating core portion.

According to some embodiments, a second hole passing between top and bottom surfaces may be defined between the plurality of insulating ribs and between the insulating core portion and the insulating upper portion.

According to some embodiments, the insulating core portion may further include a support protrusion that may protrude toward the electrode assembly to support the electrode assembly outside the insulating core portion.

According to some embodiments, a cutoff portion having a slit shape may be further provided in a lower end of the insulating core portion.

According to some embodiments, a cutoff portion having a slit shape may be further provided in a lower end of the insulating side portion.

According to some embodiments, the insulator may include at least one material of polybutylene terephthalate, polypropylene, polystyrene, or polyethylene.

According to some embodiments, the case may include a beading part that may be recessed along a direction, in which the electrode assembly extends, above the electrode assembly.

According to some embodiments, the insulating upper portion of the insulator may be interposed between the beading part and the electrode assembly.

According to some embodiments, the secondary battery may further include a second current collector plate that may be in contact with and electrically connected to a non-coating portion of the second electrode plate exposed to an upper side of the electrode assembly.

According to some embodiments, the secondary battery may further include a sub plate having one end that may be in contact with and electrically connected to an upper side of the second current collector plate and the other end that may be in contact with or electrically connected to a lower portion of the cap assembly by passing through the insulator.

According to some embodiments, the second current collector plate may be integrated with the insulator.

According to some embodiments, the insulating side portion of the insulator may have a length greater than that of the non-coating portion of the second electrode plate of the electrode assembly.

All embodiments described in this specification may be advantageously combined with one another to the extent that their respective features are compatible. In particular, the expressions "according to an embodiment," "in an embodiment," "an embodiment of the invention provides" etc. mean that the respective features may or may not be part of specific embodiments of the present invention.

The accompanying drawings are included to provide a further understanding of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate aspects of some embodiments of the present disclosure and, together with the description, serve to explain principles of the present disclosure. In the drawings:.

Embodiments of the present disclosure may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein; rather, these embodiments are provided so that those skilled in the art thoroughly understand the present disclosure. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the present disclosure to those skilled in the art.

In addition, in the following drawings, the thickness or size of each layer is exaggerated for convenience and clarity of description, and the same reference numerals in the drawings refer to the same elements. In this specification, it will also be understood that if a member A is referred to as being connected to a member B, the member A can be directly connected to the member B or indirectly connected to the member B with a member B therebetween.

The terms used in this specification are for illustrative purposes of the present disclosure only and should not be construed to limit the meaning or the scope of the present disclosure. As used in this specification, a singular form may, unless definitely indicating a particular case in terms of the context, include a plural form. Also, the expressions "comprise/include" and/or "comprising/including" used in this specification neither define the mentioned shapes, numbers, steps, operations, members, elements, and/or groups of these, nor exclude the presence or addition of one or more other different shapes, numbers, steps, operations, members, elements, and/or groups of these, or addition of these. The term "and/or" used herein includes any and all combinations of one or more of the associated listed items.

As used herein, terms such as "first," "second," etc. are used to describe various members, components, areas, layers, and/or portions. However, it is obvious that the members, components, areas, layers, and/or portions should not be defined by these terms. The terms do not mean a particular order, up and down, or superiority, and are used only for distinguishing one member, component, region, layer, or portion from another member, component, region, layer, or portion. Thus, a first member, component, region, layer, or portion which will be described may also refer to a second member, component, region, layer, or portion, without departing from the teaching of the present disclosure.

Spatially relative terms, such as "below", "beneath", "lower", "above", "upper" and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. These spatially relative terms are intended for easy comprehension of the prevent invention according to various process states or usage states of the prevent invention, and thus, the present disclosure is not limited thereto. For example, an element or feature shown in the drawings is turned inside out, the element or feature described as "beneath" or "below" may change into "above" or "upper". Thus the term "below" may encompass the term "above" or "below".

Hereinafter, aspects of some embodiments of the present disclosure will be described in more detail with reference to the accompanying drawings.

<FIG> illustrates a perspective view of a secondary battery according to some embodiments, <FIG> illustrates a cross-sectional view of the secondary battery of <FIG>, taken along the line II-II of <FIG>, and <FIG> illustrates an exploded perspective view of the secondary battery according to some embodiments.

Referring to <FIG>, a secondary battery <NUM> according to some embodiments may include a case <NUM>, an electrode assembly <NUM>, a sub plate <NUM>, a cap assembly <NUM>, an insulating gasket <NUM>, a current collector plate <NUM>, and an insulator <NUM>. However, the components of the secondary battery <NUM> are not limited thereto, and other components may be added, or at least one component may be omitted depending on the embodiments.

The case <NUM> may accommodate an electrolyte therein. The case <NUM> may function as a main body of the secondary battery <NUM> to accommodate the electrode assembly <NUM>, the cap assembly <NUM>, the insulating gasket <NUM>, a current collector plate <NUM>, and insulator <NUM> along with the electrolyte. The case <NUM> may be provided in a cylindrical shape, but the shape is not limited thereto. According to some embodiments, the case <NUM> may be made of steel, a steel alloy, aluminum, an aluminum alloy, or an equivalent thereof, but the material thereof is not limited thereto.

The electrolyte may be injected into the case <NUM> to serve so that lithium ions generated by electrochemical reaction in a first electrode plate <NUM> and a second electrode plate <NUM> inside the battery during charging and discharging are movable. The electrolyte may be a non-aqueous organic electrolyte that is a mixture of lithium salt and a high-purity organic solvent. Furthermore, the electrolyte may be a polymer using a polymer electrolyte or a solid electrolyte, and the type of the electrolyte is not limited here.

The case <NUM> may include a bottom portion <NUM> and a side portion <NUM>.

The bottom portion <NUM> may be a bottom surface of the case <NUM> facing a lower side (e.g., -z direction). The bottom portion <NUM> may be provided in an overall circular shape.

The side portion <NUM> may extend from the bottom portion <NUM> to a certain length along a first direction (e.g., z-axis direction). The side portion <NUM> may be a sidewall of the case <NUM>, which surrounds the electrode assembly <NUM>. The first direction may be a direction parallel to a direction in which a height of the secondary battery <NUM> increases (e.g., +z direction) or a direction in which the height of the secondary battery <NUM> decreases (e.g., -z direction).

According to some embodiments, during the process of manufacturing the secondary battery <NUM>, an upper portion (e.g., portion facing the +z direction) of the case <NUM> may be opened so that the electrode assembly <NUM> is injected into the case together with the electrolyte during the process of assembling the electrode assembly <NUM>. According to some embodiments, the cap assembly <NUM>, the insulating gasket <NUM>, the current collector plate <NUM>, and the insulator <NUM> may also be inserted into the case <NUM>.

The case <NUM> may further include a beading part <NUM> and a crimping part <NUM>.

The beading part <NUM> may be provided by inserting the electrode assembly <NUM> into the case <NUM> and then pressing the electrode assembly <NUM> in a second direction (e.g., x-axis direction) crossing the first direction. The beading part <NUM> may prevent the electrode assembly <NUM> from being separated from the case <NUM>. The beading part <NUM> may be recessed toward a central portion of the case <NUM>. In a state in which the cap assembly <NUM> is located at an upper portion (e.g., portion facing +z direction), an edge area of the cap assembly <NUM> may be seated on the beading part <NUM>.

In the present disclosure, the "central portion" of the component may mean a portion that is equally spaced apart from both surfaces of the component. For example, a center of the case <NUM> may mean a central portion of the case <NUM>, which is equally spaced apart from the side portions <NUM>.

The crimping part <NUM> may be located above the beading part <NUM> to extend in the second direction. In a state in which the cap assembly <NUM> is located at the upper portion (e.g., portion facing +z direction), the edge area of the cap assembly <NUM> may be located below the crimping part <NUM>. According to some embodiments, the crimping part <NUM> may press and fix the edge of the cap assembly <NUM> to seal the inside of the case <NUM>. According to some embodiments, the edge area of the cap assembly <NUM> may be interposed between the beading part <NUM> and the crimping part <NUM>. According to some embodiments, the insulating gasket <NUM> for electrical insulation may be further interposed between the cap assembly <NUM> and the case <NUM>.

The electrode assembly <NUM> is accommodated in the case <NUM> together with the electrolyte.

The electrode assembly <NUM> may include the first electrode plate <NUM>, the second electrode plate <NUM>, and a separator <NUM>. According to some embodiments, the first electrode plate <NUM> may be a negative electrode plate, and the second electrode plate <NUM> may be a positive electrode plate.

The first electrode plate <NUM> may be coated with a negative electrode active material such as graphite or carbon on at least one surface of plate-shaped metal foil made of copper (Cu) or nickel (Ni). According to some embodiments, the first electrode plate <NUM> may be provided with a negative electrode non-coating portion that is not coated with the negative electrode active material on a lower end (e.g., portion facing -z direction) thereof. The negative electrode non-coating portion may protrude in a downward direction (e.g., -z direction) of the electrode assembly <NUM>. According to some embodiments, the negative electrode non-coating portion may further protrude downward than the second electrode plate <NUM> and the separator <NUM>.

In the second electrode plate <NUM>, at least one surface of plate-shaped metal foil made of aluminum (Al) is applied to a positive electrode active material made of transition metal oxide. According to some embodiments, the second electrode plate <NUM> may be provided with a positive electrode non-coating portion that is not coated with a positive electrode active material on an upper end (e.g., portion facing +z direction) thereof. The positive electrode non-coating portion may protrude in an upward direction (e.g., +z direction) of the electrode assembly <NUM>. According to some embodiments, the positive electrode non-coating portion of the second electrode plate <NUM> may further protrude upward than the first electrode plate <NUM> and the separator <NUM>.

The separator may be located between the first electrode plate <NUM> and the second electrode plate <NUM> to prevent the first electrode plate <NUM> and the second electrode plate <NUM> from being electrically short-circuited with each other and to enable lithium ions to move only. The separator <NUM> may be made of polyethylene or polypropylene, but the embodiments according to the present disclosure are not limited thereto.

The electrode assembly <NUM> may be wound from a winding front end in a substantially cylindrical shape after the first electrode plate <NUM>, the second electrode plate <NUM>, and the separator <NUM> are stacked. According to some embodiments, in the electrode assembly <NUM>, the negative electrode non-coating portion that is not coated with the negative electrode active material may protrude downward from the first electrode plate <NUM>, and the positive electrode non-coating portion that is not coated with the positive electrode active material may protrude upward from the second electrode plate <NUM>.

The electrode assembly <NUM> may be provided with a hollow portion <NUM> in a core. According to some embodiments, the hollow portion <NUM> may serve to allow the electrolyte to quickly flow into the electrode assembly <NUM> during a process of injecting the electrolyte. According to some embodiments, the hollow portion <NUM> may serve as a passage through which a gas and/or heat generated inside the secondary battery <NUM> move to the outside.

The sub plate <NUM> may be electrically connected to the current collector plate <NUM>. According to some embodiments, the sub plate <NUM> may be electrically connected to the second current collector plate <NUM>, which will be described in more detail later. The sub plate <NUM> may be made of a separate metal plate and may be welded to the top surface of the second current collector plate <NUM>. The sub plate <NUM> may be aluminum or an aluminum alloy.

The cap assembly <NUM> may be coupled to the upper portion (e.g., portion facing the +z direction) of the case <NUM>. If the cap assembly <NUM> is coupled to the upper portion of the case <NUM>, the cap assembly <NUM> may cover the upper portion of the electrode assembly <NUM>.

The cap assembly <NUM> may include a cap-up <NUM> having a plurality of openings 141d, a safety plate <NUM> installed below the cap-up <NUM>, a connection ring <NUM> installed below the safety plate <NUM>, and a cap-down <NUM> coupled to the connection ring <NUM> and having a gas discharge hole 146b. The above-described sub plate <NUM> may be coupled to the cap-down <NUM>.

The components of the cap assembly <NUM> are not limited thereto, and other components may be added, or at least one component may be omitted depending on the embodiments.

One area of the cap-up <NUM> may be provided to be convex upward (e.g., in the +z direction) and may be electrically connected to an external circuit. According to some embodiments, the cap-up <NUM> may be provided with an opening 141d that provides a path through which the gas generated inside the case <NUM> is discharged to the outside. The cap-up <NUM> may be electrically connected to the second electrode plate <NUM> of the electrode assembly <NUM> through the sub plate <NUM>, the cap-down <NUM>, and the safety plate <NUM>. The cap-up <NUM> may be a positive electrode terminal.

The cap-up <NUM> may include a terminal part 141a, a connection part 141b, and an extension part 141c, which are sequentially arranged outward from the center.

The terminal part 141a may be flat (or approximately flat) and may be located at a substantially center of the cap-up <NUM>. According to some embodiments, when the terminal part 141a connects a plurality of secondary batteries <NUM> in series or in parallel to form a module, a positive electrode pack tab for connecting the plurality of secondary batteries <NUM> to each other is welded on a top surface of the terminal part 141a.

The connection part 141b is provided by being bent downward from an edge of the terminal part 141a and includes at least one opening 141d. The opening 141d may discharge the gas inside the case <NUM> to the outside if a vent part 143d of the safety plate <NUM> is broken.

According to some embodiments, the extension part 141c may extend outward from a lower end of the connection part 141b in a horizontal direction. An edge surface 141cc of the extension part 141c may be surrounded by the safety plate <NUM>. According to some embodiments, the bottom surface of the extension part 141c and a portion of the top surface of the extension part 141c may be in contact with the safety plate <NUM>. According to some embodiments, the edge surface may be a surface connecting the bottom surface to the top surface of the extension part.

The cap-up <NUM> may be made of any one selected from general aluminum, an aluminum alloy, steel, a steel alloy, nickel, a nickel alloy, and equivalents thereof, and the material thereof is not limited in the present invention.

The safety plate <NUM> may include a central area 143a and an edge area 143b extending outward from the central area 143a and having an end interposed between the beading part <NUM> and the crimping part <NUM> of the case <NUM> so as to be coupled to the case <NUM>. The center area 143a may be concave toward the inside of the case <NUM> compared to the edge area 143b. According to some embodiments, the safety plate <NUM> may be provided with a stepped portion because the edge area 143b is located higher than the central area 143a. The safety plate <NUM> may further include a connection area 143c connecting the center area 143a to the edge area 143b. The connection area 143c may be provided to be inclined.

The edge area 143b of the safety plate <NUM> may be arranged to be in close contact with one area (e.g., an outer circumference) of the cap-up <NUM>. According to some embodiments, the edge area 143b of the safety plate <NUM> may be bent and extend in the first direction and the second direction to surround one area (e.g., the outer circumference) of the cap-up <NUM> and may be in contact with the one area of the cap-up <NUM>. According to some embodiments, the edge of the safety plate <NUM> may surround the cap-up <NUM> and extend to an upper side of the cap-up <NUM> to cover a top surface of the cap-up <NUM>.

The safety plate <NUM> may include a vent part 143d.

The vent part 143d may be provided in the central area 143a and may be opened by a preset breaking pressure. According to some embodiments, the preset breaking pressure may be about <NUM> kgf/cm<NUM> to about <NUM> kgf/cm<NUM>, preferably about <NUM> kgf/cm<NUM> to about <NUM> kgf/cm<NUM>.

The vent part 143d may be a notch provided downward from a top surface of the central area 143a of the safety plate <NUM>. One area of the safety plate <NUM> in which the vent part 143d is provided may be thinner than the other area of the safety plate <NUM> in which the vent part 143d is not provided. According to some embodiments, the vent part 143d may be provided to have a ring shape in a plane (or in a plan view). The vent part 143d may be provided on the top surface of the safety plate <NUM> through pressing and forging processes.

If ignition occurs in the electrode assembly <NUM>, the vent part 143d may be broken to discharge a gas and heat generated during combustion, thereby reducing a risk of rupture. The vent part 143d may be spaced apart from the connection area 143c. A thickness of the vent part 143d may be about <NUM> to about <NUM>. According to some embodiments, the thickness of the vent part 143d may be a thickness from the lowest point of the notch to the bottom surface of the safety plate <NUM>. If the vent part 143d located in the central area 143a of the safety plate <NUM> is broken, the gas and heat may be more easily discharged due to an increase in breakage area, thereby preventing thermal runaway and rupture.

According to the secondary battery <NUM> according to some embodiments, if a temperature of the cell increases due to an event, or an internal pressure of the case <NUM> exceeds an operating pressure of the safety plate <NUM>, the vent part 143d may be broken by the preset breakage pressure to disperse the internal pressure due to heat exposure through the vent part 143d, thereby preventing the rupture from occurring. According to some embodiments, the secondary battery <NUM> according to some embodiments may relatively improve safety in use by providing the vent part 143d.

The safety plate <NUM> may function to block electric current and discharge the internal gas if an abnormal internal pressure occurs inside the case <NUM>.

The safety plate <NUM> may be provided as a circular metal plate and be coupled to the cap-up <NUM> and then to an upper end of the case <NUM>. The safety plate <NUM> coupled to the cap-up <NUM> may seal the opening in the upper end of the case <NUM>. In the process of assembling the secondary battery <NUM>, the electrolyte and the electrode assembly <NUM> may be inserted through the opening of the case <NUM>, and then, the safety plate <NUM> coupled to the cap-up <NUM> may be coupled to the opened upper end to seal the case <NUM>.

The safety plate <NUM> may be coupled to the upper end of the case <NUM> in a state in which the second gasket <NUM> is interposed to be prevented to electrically connected to the case <NUM>. The safety plate <NUM> may be electrically connected to the second electrode plate of the electrode assembly <NUM> through the cap-down <NUM> and the sub plate <NUM>. The safety plate <NUM> may be made of aluminum, an aluminum alloy, or equivalent. The safety plate <NUM> may be provided as a metal plate and have a thickness of about <NUM> to about <NUM>.

A connection ring <NUM> may be located between the safety plate <NUM> and the cap-down <NUM> to insulate edges of the safety plate <NUM> and the cap-down <NUM> from each other. According to some embodiments, the connection ring <NUM> may be located between an outer circumference of the safety plate <NUM> and an outer circumference of the cap-down <NUM>. The connection ring <NUM> may be made of a resin material such as polyethylene, polypropylene, or polyethylene terephthalate.

The cap-down <NUM> may be connected to a bottom surface (e.g., surface facing the -z direction) of the connection ring <NUM>. The cap-down <NUM> may be provided as a circular plate. A center of the top surface of the cap-down <NUM> may be in contact with and welded to a bottom surface of the central area 143a of the safety plate <NUM> (which, e.g., may provide a safety vent). A thickness of the center of the cap-down <NUM> may be thinner than that of each of other areas. The cap-down <NUM> may be provided with a notch or arc-shaped hole along the outer circumference of the center on the plane.

If the internal pressure of the case <NUM> increases due to the notch or hole of the cap-down <NUM>, the central area and the edge area may be separated from each other. According to some embodiments, the cap-down <NUM> may be reversed upward in the state in which the central portion is in contact with the safety plate <NUM> (which, e.g., may provide a safety vent), and thus, the central portion and the edge area may be separated from each other so as to be electrically separated from the safety plate <NUM> (which, e.g., may provide a safety vent). A gas discharge hole 146b may be defined at one side of the cap-down <NUM>. A sub plate <NUM> may be located below the cap-down <NUM>. The gas discharge hole 146b may serve to discharge the internal gas if an excessive internal pressure is generated in the case <NUM>, e.g., formed as a cylindrical can or housing. According to some embodiments, the vent part 143d of the safety plate <NUM> may be damaged by the gas discharged through the gas discharge hole 146b, and as a result, the gas may be discharged to the outside of the secondary battery <NUM>.

The insulating gasket <NUM> may function to insulate the cap assembly <NUM> from the side portion <NUM> of the case <NUM>.

The insulating gasket <NUM> may be installed in the upper opening of the case <NUM>. According to some embodiments, the insulating gasket <NUM> may be substantially arranged between the beading part <NUM>, which is provided on the side portion of the case <NUM>, and the crimping part <NUM>. For example, the insulating gasket <NUM> may be in the compressed form of the beading part <NUM> and the crimping part <NUM>. According to some embodiments, the insulating gasket <NUM> may be assembled to be in close contact between the extension part 141c of the cap-up <NUM>, the edge area 143b of the safety plate <NUM>, and the upper end of the case <NUM>. Here, the cap-up <NUM> coupled to the safety plate <NUM> may be fixed to the upper end of the case <NUM> in the state in which the insulating gasket <NUM> is interposed by the crimping part <NUM> located on the upper end of the case <NUM>.

The insulating gasket <NUM> may be made of a resin material such as polyethylene, polypropylene, polyethylene terephthalate, or the like. The insulating gasket <NUM> may prevent the cap assembly <NUM> from being separated from case <NUM>.

The current collector plate <NUM> may include a first current collector plate <NUM> and a second current collector plate <NUM>. The first current collector plate <NUM> may be in contact with and electrically connected to the first electrode plate <NUM>, and the second current collector plate <NUM> may be in contact with and electrically connected to the second electrode plate <NUM>.

The first current collector plate <NUM> may be provided as a circular metal plate that has a shape corresponding to the bottom surface (e.g., surface facing the -z direction) of the electrode assembly <NUM>. A planar size of the first current collector plate <NUM> may be equal to or less than a size of the bottom surface of the electrode assembly <NUM>.

The first current collector plate <NUM> may be fixed and electrically connected to the first electrode plate <NUM> exposed to the lower side of the electrode assembly <NUM> through welding in the state in which the top surface of the first current collector plate <NUM> is in contact with the bottom surface of the electrode assembly <NUM>. The first current collector plate <NUM> may be fixed and electrically connected to a bottom portion <NUM> by welding in a state in which a bottom surface of the first current collector plate <NUM> is in contact with the bottom portion <NUM> of the case <NUM>. The first current collector plate <NUM> may serve as a path for the current flow between the first electrode plate <NUM> of the electrode assembly <NUM> and the case <NUM>.

The second current collector plate <NUM> may be electrically connected to the second electrode plate <NUM>. The second current collector plate <NUM> may be provided as a circular metal plate that has a shape corresponding to the top surface (e.g., surface facing the +z direction) of the electrode assembly <NUM>.

The bottom surface of the second current collector plate <NUM> may be in contact with the top surface of the electrode assembly <NUM>. The second current collector plate <NUM> may be fixed and electrically connected to the second electrode plate <NUM> exposed to the upper side of the electrode assembly <NUM>.

The insulator <NUM> may be interposed between the electrode assembly <NUM> and the cap assembly <NUM> and between the electrode assembly <NUM> and the case <NUM>. The insulator <NUM> may be coupled to the electrode assembly <NUM> at an upper side of the second current collector plate <NUM>.

According to some embodiments, the insulator <NUM> may be integrated with the second current collector plate <NUM> by injection molding or assembly. For example, the second current collector plate <NUM> may be in close contact with and fixed to a lower portion of the insulator <NUM>. According to some embodiments, a portion of the edge area of the second current collector plate <NUM> may be surrounded by the insulating upper portion <NUM> of the insulator <NUM>. According to some embodiments, a portion of the upper area of the second current collector plate <NUM> may be exposed to an upper side of the insulator <NUM>.

The insulator <NUM> may insulate the second current collector plate <NUM> and the case <NUM> from each other and insulate the second electrode plate <NUM> of the electrode assembly <NUM> and the case <NUM> from each other. The insulator <NUM> may include an appropriate material to perform an insulating function. The insulator <NUM> may include at least one of polybutylene terephthalate, polypropylene, polystyrene, or polyethylene. However, the material of the insulator <NUM> is not limited thereto and may include other materials as long as the material performs the insulating function.

A structure of the insulator <NUM> may be illustrated in <FIG>, and the structure of the insulator <NUM> will be described below with reference to <FIG>. The insulator <NUM> may include an insulating upper portion <NUM>, an insulating side portion <NUM>, and an insulating core portion <NUM>. The insulator <NUM> may further include an insulating rib <NUM>. The insulator <NUM> may further include a first hole 170a and a second hole 170b.

The insulating upper portion <NUM> may be located between the second current collector plate <NUM> and the beading part <NUM> of the case <NUM>. The insulating upper portion <NUM> may prevent the second current collector plate <NUM> and the beading part <NUM> from being in contact with each other. The insulating upper portion <NUM> may have a circular ring shape covering the edge area of the second current collector plate <NUM>.

The insulating side portion <NUM> may be located between the side portion <NUM> of the case <NUM> and the electrode assembly <NUM>. The insulating side portion <NUM> may extend downward from an outer circumference of the insulating upper portion <NUM>. The insulating side portion <NUM> may be integrated with the insulating upper portion <NUM>. According to some embodiments, the insulating side portion <NUM> may cover a portion of an upper side of the sidewall of the electrode assembly <NUM>. According to some embodiments, a length of the insulating side portion <NUM> in the first direction (z) may be less than that of the electrode assembly <NUM>. The length of the insulating side portion <NUM> may be greater than that of the non-coating portion of the second electrode plate <NUM>, which protrudes upward from the electrode assembly <NUM>.

The insulating side portion <NUM> may insulate the side portion <NUM> of the case <NUM> and the second electrode plate <NUM> of the electrode assembly <NUM> from each other and may insulate the side portion <NUM> of the case <NUM> and the second current collector plate <NUM> from each other. The insulating side portion <NUM> may entirely surround an upper sidewall of the electrode assembly <NUM>. The insulating side portion <NUM> may be interposed between the side portion <NUM> of the case <NUM> and the electrode assembly <NUM>. According to some embodiments, a diameter of the insulating side portion <NUM> may be less than an inner diameter of the side portion <NUM> of the case <NUM> and greater than an outer diameter of the electrode assembly <NUM>.

The insulating core portion <NUM> may be inserted into the hollow portion <NUM> of the electrode assembly <NUM> to support the core of the electrode assembly <NUM>. The insulating core portion <NUM> may have a first hole 170a extending downward from a top surface thereof. Because the insulating core portion <NUM> has the first hole 170a, the electrolyte may be smoothly introduced into the electrode assembly <NUM> during the process of injecting the electrolyte into the electrode assembly <NUM>. According to some embodiments, the insulating core portion <NUM> may support the shape of the core of the electrode assembly <NUM> to be maintained.

The insulating core portion <NUM> may be located inside the insulating upper portion <NUM> and the insulating side portion <NUM> on the plane. According to some embodiments, the insulating core portion <NUM> may be provided to extend downward from approximately the center of the insulator <NUM> on the plane. The insulating core portion <NUM> may further protrude downward (e.g., -z direction) than the insulating side portion <NUM>. The insulating core portion <NUM> may have an overall hollow cylindrical shape. The insulating core portion <NUM> may have a smaller diameter at a lower side compared to a diameter at an upper side thereof. According to some embodiments, the insulating core portion <NUM> may have a smaller diameter and be inclined toward the lower side compared to the upper side thereof. According to some embodiments, the insulating core portion <NUM> may have a uniform thickness. As another example, a diameter of the insulating core portion <NUM> may be smaller by chamfering a lower outer surface thereof. This insulating core portion <NUM> may be easily inserted into the hollow portion <NUM> of the electrode assembly <NUM>.

According to some embodiments, a size of an end 173a of the insulating core portion <NUM> may be less than that of an intermediate portion 173b of the insulating core portion <NUM>. According to some embodiments, the insulating core portion <NUM> may be easily inserted into the hollow portion <NUM>. For example, a diameter of the end 173a of the insulating core portion <NUM> may be less than that of the intermediate portion 173b of the insulating core portion <NUM>.

The insulating core portion <NUM> may be arranged to be inclined with respect to the first direction (+z direction) in which the case <NUM> extends. According to some embodiments, the insulating core portion <NUM> may gradually decrease in size along a direction from the second current collector plate <NUM> toward the electrode assembly <NUM>. For example, a diameter 173D of the insulating core portion <NUM> may gradually decrease toward the lower side (e.g., -z direction). According to some embodiments, the secondary battery <NUM> according to some embodiments may have a structure in which the insulating core portion <NUM> is easily inserted into the hollow portion <NUM>.

The insulating core portion <NUM> may be inserted into an opening 162a of the second current collector plate <NUM>. The diameter 173D of the insulating core portion <NUM> may be less than that of the opening 162a of the second current collector plate <NUM>.

The insulating rib <NUM> may connect the insulating upper portion <NUM> to the insulating core portion <NUM>. The insulating rib <NUM> may have a uniform thickness with the insulating upper portion <NUM>. The insulating rib <NUM> may be interposed between the cap assembly <NUM> and the second current collector plate <NUM>. All of the insulating rib <NUM>, the insulating core portion <NUM>, the insulating side portion <NUM>, and the insulating upper portion <NUM> may be provided in one body. The insulating rib <NUM> may be provided in plurality to be symmetrical to each other on the plane with the insulating core portion <NUM> as the center.

According to some embodiments, a second hole 170b may be provided between adjacent insulating ribs <NUM>. The sub plate <NUM> may pass through the insulator <NUM> through the second hole 170b to electrically connect the second current collector plate <NUM> to the cap-down <NUM>. For example, one end of the sub plate <NUM> may be in contact with and coupled to the top surface of the second current collector plate <NUM>, and the other end may be in contact with and coupled to the bottom surface of the cap-down <NUM> through the insulator <NUM>. The second hole 170b may be defined at the upper side of the insulator <NUM>. For example, the second hole 170b may be defined between the insulating upper portion <NUM> and the insulating core portion <NUM> and between the plurality of insulating ribs <NUM>.

The insulator <NUM> may maintain a shape of the hollow portion <NUM> of the electrode assembly <NUM> while insulating the case <NUM> and the second current collector plate <NUM> from each other and insulating the case <NUM> and the second electrode plate <NUM> of the electrode assembly <NUM> from each other. That is, the secondary battery <NUM> may be implemented with a structure that is capable of maintaining the insulation performance and the shape of the electrode assembly <NUM> through the components of one insulator <NUM>. According to some embodiments, productivity of the secondary battery <NUM> may be relatively improved by reducing the number of manufacturing components and manufacturing processes.

The end 172a of the insulating side portion <NUM> may be chamfered. For example, the end 172a of the insulating side portion <NUM> may gradually decrease in thickness toward the lower side (e.g., -z direction). According to some embodiments, the insulator <NUM> may be easily inserted between the side portion <NUM> of the case <NUM> and the electrode assembly <NUM> through the end 172a of the insulating side portion <NUM>.

The thickness 170d of the insulator <NUM> may be about <NUM> to about <NUM>. According to some embodiments, the secondary battery <NUM> may ensure the insulating function, relatively improve ease of the manufacturing process, and achieve miniaturization.

If the thickness 170d of the insulator <NUM> is less than about <NUM>, the insulator <NUM> may be difficult to be manufactured to a uniform thickness because the thickness is too thin during the manufacturing, and thus, the insulating performance may be deteriorated, and shape deformation or distortion may occur.

If the thickness 170d of the insulator <NUM> exceeds about <NUM>, capacity of the electrode assembly <NUM> inserted into the same case <NUM> may be reduced due to the unnecessary increase in size. According to some embodiments, in the insulator <NUM>, each of the insulating upper portion <NUM>, the insulating side portion <NUM>, the insulating core portion <NUM>, and the insulating rib <NUM> may have a thickness of about <NUM> to about <NUM>.

According to some embodiments, a length <NUM> of the insulating core portion <NUM> may be about <NUM>% to about <NUM>% of the length of the electrode assembly <NUM>. If the length <NUM> of the insulating core portion <NUM> exceeds about <NUM>% of the length of the electrode assembly <NUM>, it may not be easy to insert the insulating core portion <NUM> into the hollow portion <NUM>. If the length <NUM> of the insulating core portion <NUM> is less than about <NUM>% of the length of the electrode assembly <NUM>, it may be difficult to prevent the hollow portion <NUM> from collapsing.

In the secondary battery <NUM>, because the length <NUM> of the insulating core portion <NUM> is about <NUM>% to about <NUM>% of the length of the electrode assembly <NUM>, the shape of the electrode assembly <NUM> may be easily maintained, and the insulating core portion <NUM> may be easily inserted into the hollow portion <NUM>.

Hereinafter, various embodiments of the insulator <NUM> will be sequentially described with reference to <FIG>.

<FIG> illustrates a plan view of the insulator including an example of an insulating rib, <FIG> illustrates a cross-sectional view of the insulator of <FIG>, taken along the line A-A' of <FIG> illustrates a side view of the insulator of <FIG> when viewed from the side.

<FIG> illustrates a plan view of the insulator including another example of the insulating rib, <FIG> illustrates a cross-sectional view of the insulator of <FIG>, taken along the line B-B' of <FIG> illustrates a side view of the insulator of <FIG> when viewed from the side.

Referring to <FIG>, the insulator <NUM> may include an insulating upper portion <NUM>, an insulating side portion <NUM>, an insulating core portion <NUM>, an insulating rib <NUM>, a first hole 170a, and a second hole 170b. At least one of the components of the insulator <NUM> illustrated in <FIG> may be the same as or similar to at least one (e.g., insulating upper portion) of the components of the insulator <NUM> illustrated in <FIG>, and thus, some description of the same or similar elements may be omitted below.

N (N is a natural number of <NUM> or more) number of insulating ribs <NUM> may be arranged along a circumferential direction of the insulating core portion <NUM>. Three insulating ribs <NUM> are illustrated in <FIG>, and four insulating ribs <NUM> are illustrated in <FIG>.

According to the secondary battery <NUM> according to some embodiments, a plurality of insulating ribs <NUM> may be arranged to be spaced apart from each other, and thus, sufficient support force connecting the insulating upper portion <NUM> to the insulating core portion <NUM> may be secured, and a second hole 170b through which a sub plate <NUM> passes may be defined in a space between the insulating ribs <NUM> spaced apart from each other. According to some embodiments, the secondary battery <NUM> may relatively improve a supporting force between the insulating upper portion <NUM> and the insulating core portion <NUM> and provide a second hole 170b having a compact structure.

In a process of manufacturing the secondary battery <NUM> according to some embodiments, in a state in which the insulator <NUM> is coupled to the electrode assembly <NUM>, the insulator <NUM> and the electrode assembly <NUM> may be inserted together in the case <NUM>. According to some embodiments, in the state in which the electrode assembly <NUM> inserted into the case <NUM>, the insulator <NUM> may be coupled between the electrode assembly <NUM> and the case <NUM>.

<FIG> illustrates a plan view of the insulator including further another example of an insulating rib, <FIG> illustrates a cross-sectional view of the insulator of <FIG>, taken along the line C-C' of <FIG> illustrates a side view of the insulator of <FIG> when viewed from the side;
Referring to <FIG>, the insulator <NUM> includes an insulating upper portion <NUM>, an insulating side portion <NUM>, an insulating core portion <NUM>, an insulating rib <NUM>, and a first hole 170a, and a second hole 170b. At least one of the components of the insulator <NUM> illustrated in <FIG> may be the same as or similar to at least one (e.g., insulating upper portion) of the components of the insulator <NUM> illustrated in <FIG>, and thus, some description of the same or similar elements may be omitted below.

The insulating rib <NUM> may be arranged to surround the entire inside of the insulating upper portion <NUM> and the entire outside of the insulating core portion <NUM>. According to some embodiments, the insulating rib <NUM> may extend from an inner edge of the insulating upper portion <NUM> to an upper outer edge of the insulating core portion <NUM>. This insulating rib <NUM> may be referred to as a portion of the insulating upper portion <NUM>. That is, the insulating upper portion <NUM> and the insulating rib <NUM> may have one circular plate shape connecting an upper end of the insulating core portion <NUM> to an upper end of the insulating side portion <NUM>. According to some embodiments, a second hole 170b through which a sub plate passes may be defined in the insulating rib <NUM>.

In the secondary battery <NUM>, the insulating rib <NUM> may be connected to the insulating upper portion <NUM> and a front surface of the insulating core portion <NUM> to increase in area between the insulating upper portion <NUM> and the insulating core portion <NUM>. According to some embodiments, the supporting force connecting the insulating upper portion <NUM> to the insulating core portion <NUM> may be relatively improved. According to some embodiments, the secondary battery <NUM> may relatively improve the supporting force between the insulating upper portion <NUM> and the insulating core portion <NUM> and provide the second hole 170b having a compact structure.

<FIG> illustrates a plan view of the insulator including a support protrusion, <FIG> illustrates a cross-sectional view of the insulator of <FIG>, taken along the line DDA' of <FIG> illustrates a side view of the insulator of <FIG> when viewed from the side.

Referring to <FIG>, the insulator <NUM> may include an insulating upper portion <NUM>, an insulating side portion <NUM>, an insulating core portion <NUM>, an insulating rib <NUM>, a support protrusion <NUM>, a first hole 170a, and a second hole 170b. At least one of the components of the insulator <NUM> illustrated in <FIG> may be the same as or similar to at least one (e.g., insulating upper portion) of the components of the insulator <NUM> illustrated in <FIG>, and thus, some description of the same or similar elements may be omitted below.

The support protrusion <NUM> may protrude toward the electrode assembly <NUM> to support the electrode assembly <NUM>. According to some embodiments, the support protrusion <NUM> may protrude from the insulating core portion <NUM> toward the electrode assembly <NUM> to support the electrode assembly <NUM>. According to some embodiments, the support protrusion <NUM> may be integrated with the insulating core portion <NUM>.

The support protrusion <NUM> of the insulating core portion <NUM> may support the electrode assembly <NUM> within a hollow portion <NUM> to prevent the insulator <NUM> from being separated from the electrode assembly <NUM>. According to some embodiments, coupling force between the insulator <NUM> and the electrode assembly <NUM> may be relatively improved through the support protrusion <NUM> of the insulator <NUM>.

The support protrusion <NUM> may be provided along an outer surface of the insulating core portion <NUM> in a circular ring shape or a plurality of arc shapes spaced apart from each other, but the shape is not limited thereto.

<FIG> illustrates a plan view of the insulator including an insulating core portion, <FIG> illustrates a cross-sectional view of the insulator of <FIG>, taken along the line E-E' of <FIG> illustrates a side view of the insulator of <FIG> when viewed from the side.

Referring to <FIG>, the insulator <NUM> may include an insulating upper portion <NUM>, an insulating side portion <NUM>, an insulating core portion <NUM>, an insulating rib <NUM> of an insulating core portion <NUM>, a cutoff portion of the insulating core portion <NUM>, a first hole 170a, and a second hole 170b. At least one of the components of the insulator <NUM> illustrated in <FIG> may be the same as or similar to at least one (e.g., insulating upper portion) of the components of the insulator <NUM> illustrated in <FIG>, and thus, some description of the same or similar elements may be omitted below.

The cutoff portion <NUM> of the insulating core portion <NUM> may be located on one area of the insulating core portion <NUM> facing the electrode assembly <NUM>. Due to the cutoff portion <NUM>, an area occupied by the insulating core portion <NUM> may be reduced. The cutoff portion <NUM> may be located in a lower end 173a of the insulating core portion <NUM>. The cut portion <NUM> may be in the form of a slit defined along the first direction (e.g., z-axis direction) in the insulating core portion <NUM>.

Because the area of the insulating core portion <NUM> is reduced through the cutoff portion <NUM>, the insulating core portion <NUM> may be easily inserted into a hollow. According to some embodiments, ease of assembly between the insulator <NUM> and the electrode assembly <NUM> may be relatively improved.

<FIG> illustrates a plan view of the insulator including a cutoff portion of an insulating side portion, <FIG> illustrates a cross-sectional view of the insulator of <FIG>, taken along the line F-F' of <FIG> illustrates a side view of the insulator of <FIG> when viewed from the side.

Referring to <FIG>, the insulator <NUM> may include an insulating upper portion <NUM>, an insulating side portion <NUM>, an insulating core portion <NUM>, an insulating rib <NUM>, a cutoff portion <NUM> of the insulating side portion <NUM>, a first hole 170a, and a second hole 170b. At least one of the components of the insulator <NUM> illustrated in <FIG> may be the same as or similar to at least one (e.g., insulating upper portion) of the components of the insulator <NUM> illustrated in <FIG>, and thus, some description of the same or similar elements may be omitted below.

The cutoff portion <NUM> of the insulating side portion <NUM> may be located in an area of the insulating side portion <NUM> facing the electrode assembly. Due to the cutoff portion <NUM>, an area occupied by the insulating side portion <NUM> may be reduced. The cutoff portion <NUM> may be provided in a lower end 172a of the insulating side portion <NUM>. The cutoff portion <NUM> may be in the form of a slit defined along the first direction (e.g., z-axis direction) in the lower end 172a of the insulating side portion <NUM>.

According to the secondary battery <NUM> according to some embodiments, a surface area of the insulating side portion <NUM> may be reduced through the cutoff portion <NUM>, and thus, the insulating side portion <NUM> may be easily inserted between the side portion of the case and the electrode assembly. According to some embodiments, ease of assembly between the insulator <NUM> and the electrode assembly may be relatively improved.

A secondary battery according to various embodiments of the present disclosure may have the structure in which the insulating performance and the shape of the electrode assembly are maintained through the components of the one insulator to reduce the number of components of the secondary battery and the number of manufacturing processes, thereby relatively improving the productivity and securing the integrity of the secondary battery.

The characteristics of embodiments according to the present disclosure are not limited to the characteristics mentioned above, and other characteristics not mentioned will be more clearly understood by those skilled in the art from the description below.

Claim 1:
A secondary battery (<NUM>) comprising:
an electrode assembly (<NUM>) comprising:
a first electrode plate (<NUM>);
a second electrode plate (<NUM>); and
a separator (<NUM>) between the first electrode plate (<NUM>) and the second electrode plate (<NUM>);
a case (<NUM>) configured to accommodate the electrode assembly (<NUM>);
a cap assembly (<NUM>) electrically connected to the second electrode plate (<NUM>) of the electrode assembly (<NUM>); and
an insulator (<NUM>) coupled to an upper side of the electrode assembly (<NUM>),
wherein the insulator (<NUM>) comprises:
an insulating upper portion (<NUM>) configured to cover the upper side of the electrode assembly (<NUM>);
an insulating side portion (<NUM>) between the case (<NUM>) and a side portion (<NUM>) of the electrode assembly (<NUM>); and
an insulating core portion (<NUM>) inserted into a hollow portion (<NUM>) of the electrode assembly (<NUM>) to support the electrode assembly (<NUM>).