Patent Description:
Since secondary batteries are easily applied to various product groups and has electrical characteristics such as high energy density, it is universally applied not only for a portable device but also for an electric vehicle (EV) or a hybrid electric vehicle (HEV), an energy storage system or the like, which is driven by an electric driving source. The secondary battery is attracting attention as a new environment-friendly energy source for improving energy efficiency since it gives a primary advantage of remarkably reducing the use of fossil fuels and also does not generate by-products from the use of energy at all.

A battery pack for use in electric vehicles has a structure in which a plurality of cell assemblies, each including a plurality of unit cells, are connected in series to obtain a high output. In addition, the unit cell can be repeatedly charged and discharged by electrochemical reactions among components, which include a positive electrode current collector, a negative electrode current collector, a separator, an active material, an electrolyte and the like.

Meanwhile, as the need for a large capacity structure is increasing along with the utilization as an energy storage source in recent years, there is a growing demand for a battery pack with a multi-module structure in which a plurality of battery modules, each including a plurality of secondary batteries connected in series and/or in parallel, are integrated.

When a plurality of battery cells are connected in series or in parallel to configure a battery pack, it is common to configure a battery module composed of at least one battery cell first, and then configure a battery pack by using at least one battery module and adding other components. The number of battery cells included in the battery pack, or the number of battery cells included in the battery module may be variously set according to the required output voltage or the demanded charge/discharge capacity.

The battery module includes a module case in which battery cells and various electrical parts are packaged, and a module connector connected to an external connector for electrical connection with an external device outside the module case. The external connector may be, for example, a connector for electrically connecting a plurality of battery modules.

The module connector provided in the existing battery module is securely fixed to the module case; and, therefore, when a battery module or a battery pack which is an assembly thereof is mounted and driven in a vehicle that is susceptible to vibrations or shocks, there was a fear that it could be broken without withstanding a load when receiving vibrations or shocks from the outside. <CIT> disclosed a battery module.

<CIT> refers to a battery module and battery pack including the same. The battery module comprises: a cartridge lamination having multiple secondary batteries respectively having electrode lids, while respectively accommodating at least one secondary battery among the secondary batteries, and multiple cartridges which are laminated in multiple floors; ICB housing having a bus bar connected to the electrode lid, while being coupled to one side of the cartridge lamination; a sensing connector assembly having a sensing wire electrically connected to the bus bar, and a sensing connector coupled to the end of the sensing wire, while sensing the voltages of the secondary batteries; and a connection connector assembly having a sub-connector coupled and connected to the sensing connector, a main connector coupled and connected to a circuit connector of a measurement circuit on the outside where the voltages of secondary batteries are measurable, and a connection wire for electrically connecting the sub-connector with main connector, to electrically connect the sensing connector assembly with the measurement circuit.

<CIT> relates to a connector and battery pack having the same. A contact unit is formed into a connector body. An external terminal is inserted to the contact unit. The inserted external terminal is electrically connected with the contact unit. Supporting members having elastic power are combined with the connector body and support the contact unit.

Therefore, it is an object of the present invention to provide a battery module having a module connector that imparts the elastic force capable of absorbing vibrations or shocks from the outside.

A battery module according to one embodiment of the present invention is defined in claim <NUM> and comprises: a cell assembly including at least one battery cell; a module case accommodating the cell assembly; and a module connector mounted on a mounting surface outside the module case, electrically connected to the cell assembly, and connected to an external connector outside the module case. The module connector includes a body portion connected to a terminal coupled to the battery cell, and a fastening portion configured to have elasticity on one side of the body portion facing the mounting surface of the module case.

The fastening portion of the module connector is configured to impart an elastic force in a first direction parallel to the mounting surface or in a second direction perpendicular to the mounting surface.

The fastening portion of the module connector has a portion spaced apart from the body portion to form an empty space therebetween.

The fastening portion of the module connector includes at least one pair of elastic supports that are convexly bent outward at both sides, and the module connector further includes a mounting end fastened to the mounting surface, and the elastic supports extend in a direction away from the body portion and are coupled to the mounting end at a portion facing the body portion.

The pair of elastic supports may have an elliptical shape when viewed from a third direction perpendicular to the first direction and the second direction.

The elliptical shape may be formed such that a width in the first direction is larger than that in the second direction.

The width of the pair of elastic supports spaced apart in the first direction may be equal to or smaller than the total width of the body portion measured in the first direction.

The mounting end may be mounted on the mounting surface with a sliding insert structure.

The fastening portion of the module connector may be molded from a resin material.

According to another embodiment of the present invention as defined in claim <NUM>, there is provided a battery pack comprising at least one of the above battery module and a pack case packaging the at least one battery module.

According to still another embodiment of the present invention, there is provided a device comprising at least one of the above battery pack.

According to the embodiments, by providing a structure for imparting an elastic force to a portion where a module connector is fastened in the battery module, even if a vibration or shock is transmitted from the outside of the device mounted with the battery module, it can be absorbed.

Furthermore, by providing such a vibration or shock absorbing structure to the fastening portion of the module connector, it is effective in preventing the connection portion of the module connector from being loosened or damaged.

Hereinafter, various embodiments of the present invention will be described in detail with reference to the accompanying drawings so that those skilled in the art can easily implement them. The present disclosure may be modified in various different ways within the scope of the appended claims.

Further, throughout the specification, when a part is referred to as "including" a certain component, it means that it can further include other components, without excluding the other components, unless otherwise stated.

<FIG> is a perspective view showing a battery module according to one embodiment of the present invention.

Referring to <FIG>, the battery module <NUM> according to the present embodiment includes a module connector <NUM> mounted on the outside of a module case <NUM> accommodating a cell assembly <NUM> therein. Battery cells constituting the cell assembly <NUM> may be provided as a pouch-type secondary battery, and a plurality of battery cells may be stacked and aligned in the cell assembly <NUM>. The plurality of battery cells may be electrically connected to each other, and each of the battery cells may include an electrode assembly, a battery case accommodating the electrode assembly, and an electrode lead protruding out of the battery case and electrically connected to the electrode assembly.

The battery module <NUM> may include various electric components, and may include, for example, an internal circuit board (ICB) and a battery management system (BMS). Electric components such as the ICB and BMS board may be electrically connected to the plurality of battery cells.

The module case <NUM> forms the exterior of the battery module <NUM> and accommodates the cell assembly <NUM> therein; and a busbar assembly is coupled to at least one side or both sides of the cell assembly <NUM> positioned in a direction where the electrode leads of the cell assembly <NUM> extend, and an insulating frame <NUM> may be coupled to the outside of the busbar assembly. The busbar assembly may include a busbar frame disposed to cover the cell assembly <NUM>, and a busbar fixed to the busbar frame. The busbar frame is composed of an insulator and includes a lead slot through which the electrode leads of the cell assembly <NUM> can pass. The busbar may electrically connect the electrode leads of the cell assembly <NUM>.

The module connector <NUM> can be coupled to the busbar assembly, particularly the busbar frame. A mounting surface may be formed on the busbar frame, and the module connector <NUM> may be seated on the mounting surface and coupled thereto. In this case, the module connector <NUM> and the mounting surface may have sliding grooves formed on one of them and sliding protrusions formed on the other side so as to have a fastening structure in which they are inserted into each other by sliding.

Meanwhile, the battery module <NUM> may include a flexible printed circuit board (FPC) configured to sense the battery cells inside the module case <NUM>. A terminal is coupled to the terminal portion of the flexible printed circuit board, and is exposed to the outside of the module case <NUM> and coupled to the module connector <NUM>. Accordingly, the module connector <NUM> may be electrically connected to the cell assembly <NUM> through the flexible printed circuit board.

<FIG> is a perspective view showing a connector mounted to a battery module according to one embodiment of the present disclosure, and <FIG> is a plan view of the connector shown in <FIG>.

Referring to <FIG> and <FIG>, the module connector <NUM> of the present embodiment includes a body portion <NUM> connected to a terminal and a fastening portion <NUM> used for mounting on the outside of the module case <NUM>. The terminal is electrically connected to the battery cells through the flexible printed circuit board, and the flexible printed circuit board may be connected to the terminal through a terminal portion. Accordingly, the module connector <NUM> may transmit electrical and thermal data of each battery cell to a measurement and control machine such as a BMS.

The fastening portion <NUM> of the module connector <NUM> is configured to have elasticity on one side of the body portion <NUM> facing the mounting surface of the module case <NUM>, thus absorbing shocks or vibrations. The fastening portion <NUM> is configured to impart an elastic force in a first direction (x-axis direction) parallel to the mounting surface or in a second direction (y-axis direction) perpendicular to the mounting surface. Accordingly, the module connector <NUM> is designed to impart an elastic force in the x-axis direction or in the y-axis direction according to the environmental conditions in which the module connector <NUM> is mounted, or may be also designed to impart an elastic force in both the x-axis direction and the y-axis direction. By providing the elastic force as described above, even if a load is applied in the x-axis direction or in the y-axis direction, the fastening portion <NUM> absorbs it to prevent the connection portion of the module connector <NUM> from being loosened or damaged.

In order to impart the elastic force in the x-axis direction or in the y-axis direction for the module connector <NUM>, as shown in <FIG>, the fastening portion <NUM> is spaced apart from the body portion <NUM> to form an empty space E therebetween. The fastening portion <NUM> includes a pair of elastic supports 135a and 135b that are convex outwardly at both sides, wherein the elastic supports 135a and 135b extend in a direction away from the body portion <NUM> and are coupled to a mounting end 135c at a portion facing the body portion <NUM>. As seen in <FIG>, the mounting end 135c may have a rail groove and a receiving space so as to be slidably coupled to the mounting surface.

On the other hand, as shown in <FIG>, the pair of elastic supports 135a and 135b are convexly bent outward in opposite directions from each other at both edges and extend from one surface of the body portion <NUM> to be integral with the mounting end 135c and, thus, form a closed curve. This forms an approximately elliptical shape when viewed in a third direction (z-axis direction) perpendicular to the x-axis direction and the y-axis direction, wherein the elliptical shape may have a width in the x-axis direction larger than that in the y-axis direction.

In addition, the width of the pair of elastic supports 135a and 135b spaced apart in the x-axis direction may be formed to be equal to or smaller than the width of the body portion <NUM>. In other words, when in a normal state, the maximum width of the pair of elastic supports 135a and 135b measured in the x-axis direction may be less than or equal to the entire width of the body portion <NUM> measured in the same direction. Accordingly, even if a load in the x-axis direction or in the y-axis direction is applied to the module connector <NUM>, the elastic supports 135a and 135b of the fastening portion <NUM> can protrude outside the region set by the edge of the body portion <NUM> to be prevented from interfering with the surrounding components.

The fastening portion <NUM> of the module connector <NUM> as described above may be manufactured by molding with a resin material. The elastic supports 135a and 135b and mounting end (135c) constituting the fastening portion <NUM> may be integrally formed through molding, and the fastening portion <NUM> may be integrally formed with the body portion <NUM>.

<FIG> is an enlarged partial perspective view showing a state in which a module connector is mounted in a battery module according to one embodiment of the present invention, and <FIG> is an enlarged partial front view showing a state in which a module connector is mounted in a battery module according to one embodiment of the present invention.

Referring to <FIG>, the module connector <NUM> may be aligned such that the body portion <NUM> faces outward and the fastening portion <NUM> faces the module case <NUM> incorporating the cell assembly therein, and be slidably coupled to the mounting surface <NUM> provided on the busbar assembly. Referring to <FIG>, it can be seen that the fastening portion <NUM> of the module connector <NUM> forming the empty space E is in contact with and coupled to the module case <NUM>. Therefore, the fastening portion <NUM> of the module connector <NUM> can absorb vibrations or shocks which are applied in a direction perpendicular to the main surface of the insulating frame <NUM> (y-axis direction), or vibrations or shocks which are applied in a direction being parallel to the main surface of the insulating frame <NUM> and being perpendicular to the ground (or the battery module seating surface) (x-axis direction).

In another embodiment of the present invention, a structure in which the elastic supports of the fastening portion <NUM> constituting the module connector <NUM> is formed in a plurality of pairs may be applied. That is, a plurality of elastic supports are provided on both left and right sides, respectively, and the elastic supports on both sides may be bent in opposite directions so as to be convex outwardly and thus form an elastic structure.

In an example not forming part of the claimed invention, the elastic supports of the fastening portion <NUM> constituting the module connector <NUM> are formed in a pair or a plurality of pairs on both sides, and the elastic supports on both sides may be bent in directions facing each other so as to be convex inwardly and thus form an elastic structure.

<FIG> is a perspective view showing a module connector mounted in a battery module according to the comparative example.

The module connector <NUM> shown in <FIG> includes a fastening portion <NUM> extending from one side of the body portion <NUM> to which a terminal electrically connected to a battery cell is connected. The fastening portion <NUM> is composed of a plurality of pins so that it can be securely fixed to the mounting surface provided on the outside of the module case, wherein the plurality of pins are fixed in a cluster and, thus, are difficult to provide elastic force. Therefore, unlike the fastening portion of the module connector according to the present embodiment, when affected by vibration or shock from the outside, the fastening portion <NUM> may be damaged or irreversibly deformed because it cannot absorb the vibration or shock.

Meanwhile, one or more of the battery module according to an embodiment of the present invention are packaged in a pack case to form a battery pack.

The above-mentioned battery module and battery pack comprising the same can be applied to various devices. Such a device may be applied to a vehicle such as an electric bicycle, an electric vehicle, or a hybrid vehicle, but the present invention is not limited thereto, and is applicable to various devices that can use a battery module, which also belongs to the scope of the present disclosure.

Claim 1:
A battery module (<NUM>) comprising:
a cell assembly (<NUM>) including at least one battery cell;
a module case (<NUM>) accommodating the cell assembly (<NUM>); and
a module connector (<NUM>) mounted on a mounting surface (<NUM>) outside the module case (<NUM>), electrically connected to the cell assembly (<NUM>), and connected to an external connector outside the module case (<NUM>),
wherein the module connector (<NUM>) includes:
a body portion (<NUM>) connected to a terminal coupled to the battery cell; and
a fastening portion (<NUM>) configured to have elasticity on one side of the body portion (<NUM>) facing the mounting surface (<NUM>) of the module case (<NUM>),
wherein the fastening portion (<NUM>) of the module connector (<NUM>) is configured to impart an elastic force in a first direction parallel to the mounting surface (<NUM>) and/or in a second direction perpendicular to the mounting surface (<NUM>),
wherein the fastening portion (<NUM>) of the module connector (<NUM>) has a portion spaced apart from the body portion (<NUM>) to form an empty space (E) therebetween, and
wherein the fastening portion (<NUM>) of the module connector (<NUM>) includes at least one pair of elastic supports (135a, 135b) that are convexly bent outward at both sides, and the module connector (<NUM>) further includes a mounting end (135c) fastened to the mounting surface (<NUM>), and the elastic supports (135a, 135b) extend in a direction away from the body portion (<NUM>) and are coupled to the mounting end (135c) at a portion facing the body portion (<NUM>).