Patent Description:
Currently commercialized secondary batteries include nickel cadmium batteries, nickel hydrogen batteries, nickel zinc batteries, lithium secondary batteries, etc. and the lithium secondary batteries thereamong are receiving attention according advantages of free charging/discharging, a very low self-discharge rate, and high energy density since a memory effect is barely generated compared to nickel-based secondary batteries.

Such a lithium secondary battery mainly uses a lithium-based oxide and a carbon material respectively as a positive electrode active material and a negative electrode active material. The lithium secondary battery includes an electrode assembly, in which a positive electrode plate and a negative electrode plate on which the positive electrode active material and the negative electrode active material are respectively coated are arranged with a separator therebetween, and an exterior material, i.e., a battery pouch exterior material, sealing and accommodating the electrode assembly with an electrolyte solution.

Generally, the lithium secondary battery may be classified into a can-type secondary battery, in which the electrode assembly is embedded in a metal can, and a pouch-type secondary battery, in which the electrode assembly is embedded in a pouch of an aluminum laminate sheet, according to a shape of the exterior material.

Recently, the secondary battery is widely used not only in a small-sized apparatus, such as a portable electronic device, but also in medium- and large-sized apparatuses, such as a vehicle or an energy storage apparatus. When the secondary battery is used in the medium- and large-sized apparatuses, a large number of secondary batteries are electrically connected to increase capacity and output. In particular, the pouch-type secondary battery is mostly used in such medium- and large-sized apparatuses due to easy stacking.

In order for the secondary batteries to be electrically connected inside a battery module, electrode leads may be connected to each other and a connected portion may be welded to maintain such a connected state. Moreover, the battery module may have parallel and/or series electric connection between the secondary batteries, and in this case, one end portion of the electrode lead may contact and be fixed to a bus bar for electric connection between the secondary batteries, via welding or the like.

At this time, the electric connection between the secondary batteries is often configured by bonding the electrode lead to the bus bar. In other words, in order to electrically connect the plurality of secondary batteries in parallel, the electrode leads of same polarity are connected and bonded to each other, and in order to electrically connect the plurality of secondary batteries in series, the electrode leads of different polarities are connected and bonded to each other.

Meanwhile, since the electrode lead is formed of a fragile material, while detaching or re-bonding the combined electrode lead for rework due to poor bonding or mis-bonding between the electrode lead and the bus bar, it is difficult for an operator to perform the rework because the electrode lead is very easily damaged.

Also, when a bending process of bending the electrode lead to accommodate the electrode lead on the bus bar is performed, the bent electrode lead causes a spring-back phenomenon, and thus it is difficult to adhere the electrode lead and the bus bar to each other.

Further, in the related art, the bending process of the electrode lead is performed manually to bond the electrode lead on the bus bar. However, since such a bending process is difficult to be automated and the quality of weldability varies based on the skill or condition of the operator, the quality of a product may deteriorate.

Also, since laser welding is performed while the plurality of electrode leads overlap each other during a parallel connection process of the plurality of secondary batteries, deterioration of weldability is likely to occur.

Accordingly, in order to solve issues of the related art described above, there is a need for a technology satisfactorily maintaining contact between the electrode lead and the bus bar and enabling the rework during the poor bonding or mis-bonding between the bus bar and the electrode lead.

<CIT> refers to a battery pack. An insulation plate is attached to a case housing a plurality of battery units, the plate having a ribbed structure. Each rib supports a pair of electrode tabs from protruding from different battery units, which are folded over onto each other on top of the rib. A bus bar covers each rib and electrode pair, to enable electrical coupling of the battery units.

The present disclosure is designed to solve the problems of the related art, and therefore the present disclosure is directed to providing a battery module including a bus bar assembly having improved productivity because rework is easy when a failure occurs.

In one aspect of the present disclosure, there is provided a battery module including: a cell assembly including a plurality of secondary batteries having an electrode lead formed in a shape protruding in a front-and-back direction and stacked on each other in a left-and-right direction; and a bus bar assembly configured to provide electric connection between the plurality of secondary batteries.

Here, the bus bar assembly includes: a first insulating frame where one or more insertion portions penetrating from a back surface to a front surface are formed such that a plurality of electrode leads are inserted and comprising an electric insulating material; a second insulating frame mounted on the front surface of the first insulating frame and including an electric insulating material; a first bus bar mounted on the first insulating frame, contacting one of the plurality of electrode leads inserted into each of the one or more insertion portions, the one electrode lead being located at one end of the plurality of electrode leads, and including an electric conductive material; and a second bus bar mounted on the second insulating frame, contacting one of the plurality of electrode leads inserted into each of the one or more insertion portions, which is located at the other end, and including an electric conductive material.

Also, the first bus bar and the second bus bar may include front surfaces, rear surfaces, and side surfaces based on the front-and-back direction.

Moreover, the side surfaces of the first bus bar and the second bus bar may contact a left side surface or right side surface of the electrode lead, and at least portions of the side surfaces of the first bus bar and the second bus bar may be positioned to face each other while the plurality of electrode leads are disposed to closely contact each other.

In addition, the first bus bar and the second bus bar may have a bar shape extending in an up-and-down direction or a quadrangular frame shape with a hollow center.

Further, the second insulating frame may include a penetrating portion penetrated from a rear surface to a front surface such that the plurality of electrode leads are inserted.

Also, the first bus bar may be positioned on the front surface of the first insulating frame and have at least a portion protruding forward to be inserted into the penetrating portion.

In addition, the first bus bar may be configured to further protrude forward based on a front surface of the second insulating frame.

Also, the second bus bar may be positioned on the front surface of the second insulating frame.

Further, the second bus bar may be positioned at an inner side of the penetrating portion such that the side surface faces a portion of the side surface of the first bus bar.

Also, the first bus bar may be configured to be positioned at an inner side of an insertion portion formed in the first insulating frame.

In addition, at least a portion of the second bus bar may protrude backward from a rear surface of the second insulating frame and be inserted into the insertion portion of the first insulating frame.

Also, the bus bar assembly may further include a locking member configured to lock and fix the first insulating frame and the second insulating frame to each other.

Further, the locking member may include a locking bolt.

Also, the first insulating frame may include an insertion groove configured such that at least a portion of a round rod of the locking bolt is inserted.

In addition, the second insulating frame may include a penetrating hole configured such that the round rod of the locking bolt is penetrated.

Also, the locking bolt sequentially may penetrate the penetrating hole of the second insulating frame and be inserted into and fixed to the insertion groove of the first insulating frame.

Moreover, the locking member may further include a nut or a bearing inserted into and fixed to the insertion groove and configured such that the locking bolt is inserted and locked.

Also, each of the first insulating frame and the second insulating frame may include a moving guide portion configured to guide the first insulating frame and the second insulating frame to slide in the left-and-right direction to cross each other.

Also, the moving guide portion may include: a guide groove recessed backward from a front surface of each of a top portion and bottom portion of the first insulating frame and extending in the left-and-right direction; and a guide protrusion protruding backward from a rear surface of each of a top portion and bottom portion of the second insulating frame and accommodated on an inner surface of the guide groove to move in the left-and-right direction.

Also, the one or more insertion portions perforated from the back surface to the front surface may be formed such that the plurality of electrode leads are inserted therein while being adhered to each other; the second insulating frame may comprise one or more penetrating portions perforated from a rear surface to a front surface which are formed such that the plurality of electrode leads are inserted therein while being adhered to each other, and the plurality of electrode leads may overlap each other between the first insulating plate and the second insulating plate while the first insulating frame and the second insulating frame slide in the left-and-right direction to cross each other.

In another aspect of the present disclosure, there is also provided a battery pack including at least one battery module.

In another aspect of the present disclosure, there is also provided a device including the battery pack.

According to an aspect of the present disclosure, a battery module is configured such that a first bus bar and a second bus bar of a bus bar assembly contact both side surfaces of a plurality of electrode leads inserted into an insertion portion of a first insulating frame, and thus electric connection between a plurality of secondary batteries and bus bars can be effectively achieved as the first bus bar and the second bus bar contact the both side surfaces such that the plurality of electrode leads are suitably adhered.

Moreover, according to such an aspect of the present disclosure, unlike the related art, the present disclosure can simplify manufacturing processes and reduce manufacturing costs because a bending process and a bonding process via welding or the like are not required to be performed for contact connection between an electrode lead and bus bar. In addition, since a bus bar assembly can be separated from a battery module without largely damaging the electrode lead when a defect occurs, rework is facilitated and waste of a component due to damage can be reduced.

Also, according to an aspect of the present disclosure, in a bus bar assembly, the size of a bus bar assembly can be ultimately reduced since not only a second bus bar is stably fixed to a second insulating frame without having to use a separate adhesive member by inserting a portion of the second bus bar into the second insulating frame, but also the volume occupied by the second bus bar in a front-and-back direction is largely reduced compared with the size of the second insulating frame and second bus bar in the front-and-back direction.

Moreover, according to another aspect of the present disclosure, in a bus bar assembly, since a portion of a second bus bar is positioned at an inner side of a penetrating portion formed in a second insulating frame, the size of a protruding structure of a first bus bur positioned to correspond to one side surface of the second bus bar can be largely reduced, and thus manufacturing costs can be reduced and the bus bar assembly may be manufactured to have a further stable structure.

Also, according to another aspect of the present disclosure, in a bus bar assembly, by positioning a first bus bar at an inner side of an insertion portion formed in a first insulating frame, the volume occupied by the first bus bar in a front-and-back direction can be largely reduced compared to the size of the first insulating frame and first bus bar in the front-and-back direction, thereby ultimately reducing the size of the bus bar assembly.

Moreover, according to an aspect of the present disclosure, in a locking member, by inserting and fixing a locking bolt to an insertion hole formed in a first insulating frame and a penetrating hole formed in a second insulating frame, the first insulating frame and the second insulating frame can be efficiently and stably combined and fixed to each other.

Also, according to an aspect of the present disclosure, in a guide portion, since a second insulating frame can easily slide on a first insulating frame by using a configuration of a guide groove and a guide protrusion, not only position setting for locking the first insulating frame and the second insulating frame is facilitated, but also a work of interposing a plurality of electrode leads between a first bus bar and a second bus bar is facilitated.

penetrating portion H2 of the first insulating frame 221E may overlap each other between the first insulating frame 221E and the second insulating frame 225E.

In other words, in the bus bar assembly 220E of <FIG>, the plurality of electrode leads <NUM> overlap each other between the first insulating frame 221E and the second insulating frame 225E even when some bus bars are omitted, and thus electric connection between the plurality of electrode leads <NUM> may be achieved.

As such, according to such a configuration of the present disclosure, the applied numbers of first and second bus bars <NUM> and <NUM> may be effectively reduced compared with the bus bar assembly <NUM> of an embodiment described above, and thus material costs may be reduced, thereby effectively reducing unit cost.

Also, a battery pack (not shown) according to the present disclosure may include at least two battery modules <NUM>. In particular, the at least two battery modules <NUM> may be aligned in one direction. In some cases, the battery pack may further include a heat sink (mot shown) for heat dissipation.

Also, an electronic device (not shown) according to the present disclosure may include the battery pack. For example, the battery pack may be accommodated inside an outer case of the electronic device. Also, the electronic device may be a type of transportation, such as an electric bicycle, or a machine tool.

Meanwhile, in the present specification, the terms indicating directions, such as up, down, left, right, front, and back, are used but it would be obvious to one of ordinary skill in the art that the terms are used only for convenience of description and may vary according to a position of a target object, a position of an observer, or the like. a sealing portion. Also, the electrode assembly and the electrolyte solution may be accommodated in the accommodating portion.

Also, the electrode assembly is an assembly of electrodes and a separator, and may be configured in a shape in which one or more positive electrode plates and one or more negative electrode plates are arranged with the separator therebetween. Also, a first electrode tab is provided at a first electrode plate of the electrode assembly and one or more first electrode tabs may be connected to a first electrode lead <NUM>.

Here, the first electrode lead <NUM> has one end connected to the first electrode tab and the other end exposed to the outside of the pouch, and such an exposed portion may function as an electrode terminal of the secondary battery <NUM>, for example, a positive electrode terminal of the secondary battery <NUM>.

Also, a second electrode tab is provided at a second electrode plate of the electrode assembly and one or more second electrode tabs may be connected to a second electrode lead <NUM>. The second electrode lead <NUM> has one end connected to the second electrode tab and the other end exposed to the outside of the pouch, and such an exposed portion may function as an electrode terminal of the secondary battery <NUM>, for example, a negative electrode terminal of the secondary battery <NUM>.

Here, the first electrode tab and the second electrode tab included in the secondary battery <NUM> may be a positive electrode tab or a negative electrode tab, and the first electrode lead <NUM> and the second electrode lead <NUM> may be a positive electrode lead or a negative electrode lead. Moreover, the first and second electrode leads <NUM> and <NUM> may be electrode leads of different polarities. For example, the first electrode lead <NUM> may be a positive electrode lead and the second electrode lead <NUM> may be a negative electrode lead.

Further, the positive electrode lead and the negative electrode lead may be provided on opposite directions based on the center of the secondary battery <NUM>. For example, as shown in <FIG> and <FIG>, each secondary battery <NUM> may be configured such that the first and second electrode leads <NUM> and <NUM> having different polarities protrude forward and backward.

As such, according to such a configuration of the present disclosure, there is no interference between the positive electrode lead and the negative electrode lead in one secondary battery <NUM>, and thus the area of an electrode lead <NUM> may be increased. Here, the electrode lead <NUM> includes the first electrode lead <NUM> and the second electrode lead <NUM>.

Also, the first and second electrode leads <NUM> and <NUM> may be configured in a plate shape. In particular, the first and second electrode leads <NUM> and <NUM> may protrude in a horizontal direction while a wide area is erected to face the left and the right.

Also, the plurality of secondary batteries <NUM> may be included in the battery module <NUM> and stacked on each other in at least one direction. For example, as shown in <FIG> and <FIG>, the plurality of pouch type secondary batteries <NUM> may be stacked on each other in parallel in a left-and-right direction.

Here, each pouch type secondary battery <NUM> may be arranged to be perpendicularly erected approximately on the ground such that, when viewed in a direction indicated by an arrow F (shown in <FIG>), two wide areas are respectively positioned at the left and the right and a sealing portion is positioned at top, bottom, front, and back. In other words, each secondary battery <NUM> may be erected in an up-and-down direction. Meanwhile, in the present specification, unless otherwise specified, up, down, front, back, left, and right directions are based on the direction indicated by the arrow F.

Since the configuration of the pouch type secondary battery <NUM> described above is obvious to one of ordinary skill in the art of the present disclosure, more detailed descriptions are omitted. Also, the battery module <NUM> according to the present disclosure may employ various secondary batteries <NUM> well-known at the time of application of the present disclosure.

<FIG> is a front view schematically illustrating a first bus bar and a first insulating frame, which are isolated partial components with respect to a battery module, according to an embodiment of the present disclosure. <FIG> is a front view schematically illustrating a second bus bar and a second insulating frame, which are isolated partial components with respect to a battery module, according to an embodiment of the present disclosure. <FIG> is a rear view schematically illustrating a second insulating frame that is an isolated partial component with respect to a battery module, according to an embodiment of the present disclosure. <FIG> is a front view schematically illustrating a battery module according to an embodiment of the present disclosure.

Referring to <FIG>, the bus bar assembly <NUM> may be configured to provide electric connection between the plurality of secondary batteries <NUM>. In particular, the bus bar assembly <NUM> may be positioned at each of the front and back of the cell assembly <NUM> including the plurality of secondary batteries <NUM> where the electrode lead <NUM> is formed on both sides.

Here, the bus bar assembly <NUM> may include a first insulating frame <NUM>, a second insulating frame <NUM>, a first bus bar <NUM>, and a second bus bar <NUM>.

In particular, the first insulating frame <NUM> may include an electric insulating material. Also, the electric insulating material may be, for example, a plastic material. Also, the first insulating frame <NUM> may include one or more insertion portion H1 penetrating from a rear surface to a front surface such that the plurality of electrode leads <NUM> are inserted.

Moreover, the insertion portion H1 may have an opening having the size into which the plurality of electrode leads <NUM> are insertable. For example, as shown in <FIG>, three insertion portions H1 may be formed in the first insulating frame <NUM>, and each insertion portion H1 may have the opening having the size corresponding to a vertical length of the electrode lead <NUM>.

Also, the insertion portion H1 may be an opening perforated at an inner side of the first insulating frame <NUM>. The plurality of electrode leads <NUM> may be easily inserted into the insertion portion H1 having such an opening, in the front-and-back direction.

Alternatively, the insertion portion H1 may be an opening extending from the center of the first insulating frame <NUM> to an upper end portion or a lower end portion. In the insertion portion H1 having such a structure, since the plurality of electrode leads <NUM> are not only inserted into the first insulating frame <NUM> in the front-and-back direction, but also into the center from the upper end portion or the lower end portion of the first insulating frame <NUM>, insertion is facilitated in various directions and thus manufacture efficiency may be increased.

The second insulating frame <NUM> may include an electric insulating material. The electric insulating material may be, for example, a plastic material. Also, the second insulating frame <NUM> may be mounted on a front surface of the first insulating frame <NUM>. The second insulating frame <NUM> may be configured to slide in a left-and-right direction while being mounted on the front surface of the first insulating frame <NUM>.

Moreover, the first bus bar <NUM> may include an electric conductive material having relatively high electric conductivity. For example, the electric conductive material may be copper or aluminum.

Also, the first bus bar <NUM> may be mounted on the first insulating frame <NUM>. In other words, the first bus bar <NUM> may be fixed while being mounted on the first insulating frame <NUM>. Moreover, a method of fixing the first bus bar <NUM> to the first insulating frame <NUM> is not limited to a specific method, and for example, an adhesive may be coated on an outer surface of the first insulating frame <NUM> and then the first bus bar <NUM> may be adhered to a region where the adhesive is coated.

Also, the first bus bar <NUM> may be configured such as to contact one of the plurality of electrode leads <NUM> inserted into the insertion portion H1 of the first insulating frame <NUM>. In particular, the first bus bar <NUM> may contact one side surface of the electrode lead <NUM> positioned at one end (a leftmost or rightmost side) among the plurality of electrode leads <NUM> adhered in the left-and-right direction.

Also, the second bus bar <NUM> may be mounted on the second insulating frame <NUM>. In other words, the second bus bar <NUM> may be fixed while being mounted on the second insulating frame <NUM>. A method of fixing the second bus bar <NUM> to the second insulating frame <NUM> is not limited to a particular method, and for example, an adhesive may be coated on an outer surface of the second insulating frame <NUM> and then the second bus bar <NUM> may be adhered to a region where the adhesive is coated.

Moreover, the second bus bar <NUM> may be configured to contact one of the plurality of electrode leads <NUM> inserted into the insertion portion H1 of the second insulating frame <NUM>. In particular, the second bus bar <NUM> may contact the other side surface of the electrode lead <NUM> positioned at the other end (the leftmost or rightmost side) among the plurality of electrode leads <NUM> adhered in the left-and-right direction.

For example, as shown in <FIG>, when the first bus bar <NUM> contacts the electrode lead <NUM> positioned at the leftmost side among the plurality of electrode leads <NUM> inserted into the insertion portion H1, the second bus bar <NUM> may contact the electrode lead <NUM> positioned at the rightmost side and inserted into the insertion portion H1.

Thus, according to such a configuration of the present disclosure, by configuring the first and second bus bars <NUM> and <NUM> to contact the both side surfaces of the plurality of electrode leads <NUM> inserted into the insertion portion H1, the first and second bus bars <NUM> and <NUM> are able to pressurize, from the both side surfaces, the plurality of electrode leads <NUM> to be suitably adhered, thereby effectively achieving electric connection between a plurality of secondary batteries and a bus bar.

Moreover, in the present disclosure, unlike the related art, manufacturing processes are simplified and manufacturing costs are reduced because a bending process and a bonding process via welding or the like are not required to be performed for contact connection between an electrode lead and bus bar. In addition, since a bus bar assembly may be separated from a battery module without largely damaging the electrode lead when a defect occurs, rework is facilitated and waste of a component due to damage may be reduced.

<FIG> is a partial cross-sectional view schematically illustrating a cross section of a battery module taken along a line A-A' of <FIG>.

Referring to <FIG> together with <FIG>, the first bus bar <NUM> may include, based on the front-and-back direction, a front surface 231a, a rear surface 231b, and a side surface 231c.

Here, the side surface 231c of the first bus bar <NUM> may contact a left side surface or right side surface of the electrode lead <NUM>. For example, as shown in <FIG>, the right side surface 231c of the first bus bar <NUM> may contact a left side surface of the first electrode lead <NUM>.

Similarly, the second bus bar <NUM> may include, based on the front-and-back direction, a front surface 235a, a rear surface 235b, and a side surface 235c.

Here, the side surface 235c of the second bus bar <NUM> may contact the left side surface or right side surface of the electrode lead <NUM>. For example, as shown in <FIG>, the left side surface 235c of the second bus bar <NUM> may contact a right side surface of the second electrode lead <NUM>.

Also, the first bus bar <NUM> and the second bus bar <NUM> may be positioned so that at least the side surfaces thereof at least partially face each other in a state where the plurality of electrode leads <NUM> are interposed between the first bus bar <NUM> and the second bus bar <NUM> and adhered to each other. In other words, the side surface of the first bus bar <NUM> may contact one side surface of the electrode lead <NUM> positioned at the end of the plurality of electrode leads <NUM> adhered to each other, and the side surface of the second bus bar <NUM> may contact the other side surface of the electrode lead <NUM> positioned at the other end of the plurality of electrode leads <NUM> adhered to each other.

As such, according to such a configuration of the present disclosure, since the first and second bus bars <NUM> and <NUM> are formed in a structure capable of effectively contacting the one side surface and the other side surface of the plurality of electrode leads <NUM> adhered to each other, an adhered state between the plurality of electrode leads <NUM> may be maintained and electric connection between the plurality of secondary batteries <NUM> may be effectively achieved.

Referring back to <FIG>, the first bus bar <NUM> may have a bar shape extending in the up-and-down direction. In particular, the first bus bar <NUM> may be formed in such a manner that the side surface 231c has the size equal to or larger than that of a side H1c of the insertion portion H1. Also, the first bus bar <NUM> may be positioned such that the side surface 231c is parallel to the other side H1c of the insertion portion H1 of the insertion portion H1 when viewed from the front. In other words, the first bus bar <NUM> may be positioned such that, when viewed from the front, the side surface 231c and the other side H1c of the insertion portion H1 contact each other.

For example, as shown in <FIG>, the three first bus bars <NUM> may have a bar shape extending in the up-and-down direction. Also, the three first bus bars <NUM> may be positioned such that, when viewed from the front, the right side surface 231c overlap the left side H1c of the insertion portion H1.

However, the shape of the first bus bar <NUM> is not necessarily limited to a bar shape, and the first bus bar <NUM> may have a quadrangular frame shape with a hollow center, like a second bus bar 235B of <FIG>. In other words, the first bus bar <NUM> includes an upper end portion and a lower end portion extending in the left-and-right direction, and may include a both side portions extending in the up-and-down direction to connect the upper end portion and the lower end portion.

As such, according to such a configuration of the present disclosure, since the first bus bar <NUM> is formed such that the side surface of the electrode lead <NUM> inserted through the insertion portion H1 of the first insulating frame <NUM> is easily contacted, electric connection between the electrode lead <NUM> and the first bus bar <NUM> may be easily achieved.

In particular, a second bus bar 235A may have a bar shape extending in the up-and-down direction. In particular, the second bus bar 235A may be formed such that the side surface 235c thereof may have the size equal to or larger than that of a side H2c of a penetrating portion H2. Also, the other side surface 235c of the second bus bar 235A may be positioned to be parallel to the side H2c of the penetrating portion H2 when viewed from the front. In other words, the other side surface 235c of the second bus bar 235A and the side H2c of the penetrating portion H2 may be positioned to contact each other.

Moreover, the second bus bar 235B according to another embodiment may have a quadrangular frame shape with a hollow center. In other words, the second bus bar 235B includes an upper end portion <NUM> and a lower end portion <NUM> extending in the left-and-right direction, and may include a both side portions <NUM> extending in the up-and-down direction to connect the upper end portion <NUM> and the lower end portion <NUM>.

For example, as shown in <FIG>, one second bus bar 235A may have a bar shape extending in the up-and-down direction and one second bus bar 235B may have a quadrangular shape with a hollow center. Also, the two second bus bars 235A and 235B may be positioned such that left side portions thereof overlap the right side H2c of the penetrating portion H2 when viewed from the front.

Accordingly, the second bus bar 235B is formed to easily contact the side surface of the plurality of electrode leads <NUM> inserted through the penetrating portion H2 of the second insulating frame <NUM>, and thus electric connection between the plurality of electrode leads <NUM> and the second bus bar 235B may be easily achieved.

Also, in the second insulating frame <NUM>, one or more penetrating portion H2 penetrated from the rear surface to the front surface may be formed such that the plurality of electrode leads <NUM> are inserted.

Moreover, the penetrating portion H2 may have an opening having the size into which the plurality of electrode leads <NUM> are insertable. For example, as shown in <FIG>, the second insulating frame <NUM> may include three penetrating portions H2 and each penetrating portion H2 may have an opening having the size corresponding to a vertical length of the electrode lead <NUM>.

Also, the penetrating portion H2 may be an opening extending from the center of the second insulating frame <NUM> to the upper end portion or the lower end portion. In such a penetrating portion H2, the plurality of electrode leads <NUM> are insertable not only to the second insulating frame <NUM> in the front-and-back direction, but also to the center from the upper end portion or lower end portion of the second insulating frame <NUM>, and thus manufacture efficiency may be increased.

Referring back to <FIG> together with <FIG>, at least one portion of the penetrating portion H2 may be positioned to face the insertion portion H1 of the first insulating frame <NUM>. In other words, the electrode lead <NUM> may be configured to penetrate the insertion portion H1 and then penetrate the penetrating portion H2 again.

Referring to <FIG> and <FIG>, the first bus bar <NUM> may be positioned at the front surface of the first insulating frame <NUM>. In particular, the first bus bar <NUM> may be positioned such that the side surface 231c of the first bus bar <NUM> and an inner side surface of the first insulating frame <NUM> are connected in the front-and-back direction.

Also, the first bus bar <NUM> may be formed such that at least a portion protrudes forward to be inserted into the penetrating portion H2. Moreover, the first bus bar <NUM> may protrude to face at least a portion of the second bus bar <NUM>. For example, as shown in <FIG>, the first bus bar <NUM> may protrude to face one side surface of the second bus bar <NUM>.

Moreover, the first bus bar <NUM> may be configured to further protrude forward based on the front surface of the second insulating frame <NUM>. In other words, the first bus bar <NUM> may protrude externally by penetrating the insertion portion H1 to correspond to one side surface of the second bus bar <NUM> while the plurality of electrode leads <NUM> are disposed.

Also, the second bus bar <NUM> may be positioned at the front surface of the second insulating frame <NUM>. Moreover, the second bus bar <NUM> may be positioned such that the side surface 235c of the second bus bar <NUM> and an inner side surface of the penetrating portion H2 of the second insulating frame <NUM> are connected in the front-and-back direction.

<FIG> is a front view schematically illustrating a first bus bar and a first insulating frame, which are isolated partial components with respect to a battery module, according to another embodiment of the present disclosure. <FIG> is a front view schematically illustrating a second bus bar and a second insulating frame, which are isolated partial components with respect to a battery module, according to another embodiment of the present disclosure. <FIG> is a front view schematically illustrating a battery module according to another embodiment of the present disclosure. Also, <FIG> is a partial cross-sectional view schematically illustrating a cross section of a battery module taken along a line A-A' of <FIG>.

First, referring to <FIG>, in a bus bar assembly 220C according to another embodiment of the present disclosure, configurations of a first insulating frame 221C and a first bus bar 231C of <FIG> may be the same as a configuration of the first insulating frame <NUM> of <FIG> according to an embodiment of the present disclosure described above. Accordingly, detailed descriptions about the first insulating frame 221C and the first bus bar 231C of <FIG> will be omitted.

Meanwhile, referring back to <FIG>, unlike the second bus bar <NUM> positioned at the front surface of the second insulating frame <NUM> of <FIG>, at least a portion of the second bus bar <NUM> of <FIG> may be positioned inside the penetrating portion H2. Also, a side surface of the second bus bar <NUM> may face at least a portion of a side surface of the first bus bar 231C.

Moreover, a portion of the second bus bar <NUM> may be inserted into a second insulating frame 225C. Also, an insert injection method may be used as a method for inserting the portion of the second bus bar <NUM> into the second insulating frame 225C.

For example, a method of manufacturing the second insulating frame 225C into which the second bus bar <NUM> is inserted may include: (a) preparing the second bus bar <NUM> of electric conductivity, whose external shape is plasticized via press; (b) mounting and fixing the second bus bar <NUM> inside a mold; and (c) injecting a melted insulating material into the mold to combine with at least a portion of the second bus bar <NUM> and performing casting by solidifying the melted material.

As such, according to such a configuration of the present disclosure, by inserting the portion of the second bus bar <NUM> into the second insulating frame <NUM>, not only the second bus bar <NUM> second bus bar <NUM> is stably fixed to the second insulating frame 225C without having to use a separate adhesive member, but also the volume occupied by the second bus bar <NUM> of <FIG> in the front-and-back direction is largely reduced compared with the size of the second insulating frame <NUM> and second bus bar <NUM> of <FIG> in the front-and-back direction, and thus the size of the bus bar assembly 220C may be ultimately reduced.

Moreover, a portion of the second bus bar <NUM>, which is not inserted into the second insulating frame 225C, may be positioned inside the penetrating portion H2. For example, as shown in <FIG>, in a second bus bar 235D having the rectangular frame shape, the upper end portion <NUM> and the lower end portion <NUM> may be inserted into the second insulating frame 225C, and the both side portions <NUM> connecting the upper end portion <NUM> and the lower end portion <NUM> may be positioned inside the penetrating portion H2 of the second insulating frame 225C.

Also, referring to <FIG>, in a second bus bar 235C having the bar shape, one side portion <NUM> may be inserted into the second insulating frame 225C and the other side portion may be externally exposed by being positioned inside the penetrating portion H2.

In other words, the second bus bar <NUM> of <FIG> may be positioned to correspond to the first bus bar 231C positioned at the front surface of the first insulating frame 221C. In other words, the first bus bar 231C may be positioned to correspond to the side surface of the second bus bar <NUM> as at least a portion is inserted into the penetrating portion H2 of the second insulating frame 225C. Accordingly, the plurality of electrode leads <NUM> inserted into the insertion portion H1 and the penetrating portion H2 may be disposed on the side surface of the first bus bar 231C and the side surface of the second bus bar <NUM>.

As such, according to such a configuration of the present disclosure, by positioning the portion of the second bus bar <NUM> inside the penetrating portion H2, the size of a structure of the first bus bar 231C protruding forward to correspond to the one side surface of the second bus bar <NUM> may be largely reduced, and thus the bus bar assembly 220C may be manufactured with low material costs and a stable structure.

Referring to <FIG>, a bus bar assembly 220D according to another embodiment of the present disclosure may be configured such that a first bus bar 231D is positioned inside the insertion portion H1 formed in a first insulating frame 221D. In other words, the first bus bar 231D may be positioned inside the insertion portion H1 without protruding forward based on a front surface of the first insulating frame 221D.

As such, according to such a configuration of the present disclosure, by positioning the first bus bar 231D inside the insertion portion H1 formed in the first insulating frame 221D, the volume occupied by the first bus bar 231D of <FIG> in the front-and-back direction may be largely reduced compared with the size of the first insulating frame <NUM> and first bus bar <NUM> of <FIG> in the front-and-back direction, and thus the size of the bus bar assembly 220D may be ultimately reduced.

Moreover, a portion of the first bus bar 231D may be inserted into the first insulating frame 221D such as to be positioned inside the insertion portion H1. Also, an insert injection method may be used as a method of inserting the portion of the first bus bar 231D into the first insulating frame 221D.

For example, a method of manufacturing the first insulating frame 221D into which the portion of the first bus bar 231D is inserted may include: (a) preparing the first bus bar 231D of electric conductivity, whose external shape is plasticized via press; (b) mounting and fixing the first bus bar 231D inside a mold; and (c) injecting a melted insulating material into the mold to combine with at least a portion of the first bus bar 231D and performing casting by solidifying the melted material.

As such, according to such a configuration of the present disclosure, by inserting the portion of the first bus bar 231D into the first insulating frame 221D, the first bus bar 231D may be fixed to the first insulating frame 221D stably without having to use a separate adhesive material.

Also, at least a portion of the second bus bar <NUM> of <FIG> may protrude backward from a rear surface of a second insulating frame 225D. In other words, at least a portion of the second bus bar <NUM> may protrude to be inserted into the insertion portion H1 formed in the first insulating frame 221D while the second bus bar <NUM> is combined to the second insulating frame 225D.

For example, as shown in <FIG>, in a second bus bar 235F of a quadrangular frame shape, the upper end portion <NUM> and the lower end portion <NUM> may be inserted into the second insulating frame 225D, and the both side portions <NUM> connecting the upper end portion <NUM> and the lower end portion <NUM> may protrude backward based on a rear surface of the second insulating frame 225D.

Moreover, in a second bus bar 235E of a bar shape, the front end portion 235a may be inserted into the second insulating frame 225D or a front surface may be adhered to a rear surface of the second insulating frame 225D. Also, the rear end portion 235b of the second bus bar 235E may protrude such that at least a portion is inserted into the insertion portion H1 formed in the first insulating frame 221D.

As such, according to such a configuration of the present disclosure, compared with the second insulating frame <NUM> of <FIG> and the second insulating frame 225C of <FIG>, the second insulating frame 225D of <FIG> does not require a separate penetrating portion for inserting the electrode lead <NUM>, and thus has a simple structure and simplified manufacturing processes.

Moreover, since components, such as the electrode lead <NUM>, the first bus bar 231D, the second bus bar <NUM>, etc., which are internal components of the bus bar assembly 220D, are vulnerable to an external impact, the second insulating frame 225D that does not include the penetrating portion may effectively protect an internal structure of the bus bar assembly 220D from the outside.

<FIG> is a partial cross-sectional view schematically illustrating a cross section of a battery module taken along a line B-B' of <FIG>.

Referring to <FIG> together with <FIG>, the bus bar assembly <NUM> may include a locking member <NUM> configured such that the first insulating frame <NUM> and the second insulating frame <NUM> are locked and fixed to each other.

Her, the locking member <NUM> may be configured to such that the first insulating frame <NUM> and the second insulating frame <NUM> are locked and fixed to each other while the first insulating frame <NUM> and the second insulating frame <NUM> slide in the left-and-right direction indicated by arrows E to cross each other.

In other words, when the first and second insulating frames <NUM> and <NUM> slide in the left-and-right direction to cross each other, the locking member <NUM> may lock and fix the first insulating frame <NUM> and the second insulating frame <NUM> while the plurality of electrode leads <NUM> inserted into the insertion portion H1 or into the insertion portion H1 and the penetrating portion H2 are disposed between the first bus bar <NUM> and the second bus bar <NUM>.

In particular, the second bus bar <NUM> may pressurize one side of the plurality of electrode leads <NUM> while moving in direction where the first bus bar <NUM> is positioned, and the other side of the pressurized plurality of electrode leads <NUM> may contact a side surface of the first bus bar <NUM>. As a result, both sides of the plurality of electrode leads <NUM> inserted into the insertion portion H1 or into the insertion portion H1 and the penetrating portion H2 may be pressurized and fixed by the first bus bar <NUM> and the second bus bar <NUM>.

In particular, the locking member <NUM> may include a locking bolt <NUM>.

Here, the locking bolt <NUM> may include a head and a round rod extending in one direction from the head. A thread may be formed on the round rod.

Also, as shown in <FIG>, the first insulating frame <NUM> may include an insertion groove G configured such that at least a portion of the round rod of the locking bolt <NUM> is inserted. For example, the insertion groove G may be formed on a side surface portion contacting an outer circumference of the first insulating frame <NUM>. Also, the insertion groove G may be formed on the front surface of the first insulating frame <NUM>.

Moreover, the second insulating frame <NUM> may include a penetrating hole H3 through which the round rod of the locking bolt <NUM> passes. For example, the penetrating hole H3 may be formed on a side end portion contacting an outer circumference of the second insulating frame <NUM>. Alternatively, the penetrating portion H3 may be formed on a rear surface of the second insulating frame <NUM>.

Then, the locking bolt <NUM> may sequentially penetrate the penetrating hole H3 of the second insulating frame <NUM> and inserted and fixed to the insertion groove G of the first insulating frame <NUM>.

For example, as shown in <FIG>, the insertion groove G may be formed on the front surface of each of the upper end portion and the lower end portion of the first insulating frame <NUM>. Also, as shown in <FIG>, the penetrating hole H3 may be formed on the rear surface of the second insulating frame <NUM>. Also, as shown in <FIG>, the two locking bolts <NUM> may each sequentially penetrate the penetrating hole H3 of the second insulating frame <NUM> and inserted and fixed to the insertion groove G of the first insulating frame <NUM>.

As such, according to such a configuration of the present disclosure, in the locking member <NUM>, by inserting and fixing the locking bolt <NUM> to the insertion groove G formed in the first insulating frame <NUM> and the penetrating hole H3 formed in the second insulating frame <NUM>, the first insulating frame <NUM> and the second insulating frame <NUM> may be efficiently and stably combined and fixed to each other.

The locking member <NUM> may further include a nut or a bearing <NUM> inserted and fixed to the insertion groove G. In other words, the bearing <NUM> may be configured such that the locking bolt <NUM> is inserted and locked.

As such, according to such a configuration of the present disclosure, by locking the locking bolt <NUM> to the bearing <NUM> including a solid metal material inserted and fixed into the insertion groove G, further stable fixation may be achieved than when the locking bolt <NUM> is inserted and fixed to the insertion groove G.

Referring back to <FIG> together with <FIG>, a moving guide portion <NUM> configured to guide the first insulating frame <NUM> and the second insulating frame <NUM> to slide in the left-and-right direction to cross each other may be formed in the first insulating frame <NUM> and the second insulating frame <NUM>.

In particular, the moving guide portion <NUM> may include a guide groove <NUM> and a guide protrusion <NUM>.

Here, the guide groove <NUM> may be recessed backward from the front surface of the first insulating frame <NUM>. In other words, the guide groove <NUM> may be a groove having one portion among a front surface recessed backward than the remaining portions. For example, as shown in <FIG>, the two guide grooves <NUM> may be formed on a front surface of each of an upper end portion and a lower end portion of the first insulating frame <NUM>.

Also, the guide groove <NUM> may extend in the left-and-right direction so as to guide the second insulating frame <NUM> to slide in the left-and-right direction. Further, the insertion groove G may be formed on a side wall of an end portion where the guide groove <NUM> is ended.

In other words, by sliding the second insulating frame <NUM> in the left-and-right direction along the guide groove <NUM> and then enabling the locking bolt <NUM> to sequentially penetrate the penetrating hole H3 of the second insulating frame <NUM> and be inserted and fixed to an insertion groove of the first insulating frame <NUM>, the first insulating frame <NUM> and the second insulating frame <NUM> may be locked and fixed to each other while the plurality of electrode leads <NUM> are interposed between the first bus bar <NUM> and the second bus bar <NUM>.

Referring to <FIG> and <FIG>, the guide protrusion <NUM> may be formed to protrude backward from the rear surface of the second insulating frame <NUM>. Also, the guide protrusion <NUM> may be formed to correspond to the guide groove <NUM> formed on the front surface of the first insulating frame <NUM>. For example, when the guide groove <NUM> is formed to have a rounded inner surface on a vertical cross section, an outer surface of the guide protrusion <NUM> may have a round protruding shape. When the guide groove <NUM> is formed to have an inner surface angulated on the vertical cross section, the outer surface of the guide protrusion <NUM> may have an angulated protrusion shape.

Moreover, the guide protrusion <NUM> may be accommodated on an inner surface of the guide groove <NUM> and move in the left-and-right direction. In other words, the guide protrusion <NUM> may be formed to move in the left-and-right direction by being accommodated on the inner surface of the guide groove <NUM> extending in the left-and-right direction. For example, as shown in <FIG>, the two guide protrusions <NUM> may be formed on a rear surface of each of the upper end portion and the rear end portion of the second insulating frame <NUM>.

As such, according to such a configuration of the present disclosure, the moving guide portion <NUM> enables the second insulating frame <NUM> to easily slide on the first insulating frame <NUM> by using configurations of the guide groove <NUM> and the guide protrusion <NUM>, thereby not only facilitating position setting for locking the first insulating frame <NUM> and the second insulating frame <NUM>, but also facilitating a work of disposing the plurality of electrode leads <NUM> between the first bus bar <NUM> and the second bus bar <NUM>.

<FIG> is a front view schematically illustrating a battery module according to another embodiment of the present disclosure.

Referring to <FIG>, another bus bar assembly 220E of the present disclosure may include only a part of the plurality of first bus bars <NUM> and plurality of second bus bars <NUM>, unlike the bus bar assembly <NUM> of an embodiment described above. For example, all of first bus bars of a first insulating frame 221E and a second bus bar of a bar shape of a second insulating frame 225E may not be provided.

In this case, while the first insulating frame 221E and the second insulating frame 225E slid in the left-and-right direction to cross each other, the plurality of electrode leads <NUM> inserted into an insertion portion (not shown) of the first insulating frame 221E and the penetrating portion H2 of the first insulating frame 221E may overlap each other between the first insulating frame 221E and the second insulating frame 225E.

Meanwhile, in the present specification, the terms indicating directions, such as up, down, left, right, front, and back, are used but it would be obvious to one of ordinary skill in the art that the terms are used only for convenience of description and may vary according to a position of a target object, a position of an observer, or the like.

While the present disclosure has been particularly shown and described with reference to exemplary embodiments thereof, it will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without.

Claim 1:
A battery module (<NUM>) comprising:
a cell assembly (<NUM>) comprising a plurality of secondary batteries (<NUM>) having an electrode lead (<NUM>) formed in a shape protruding in a front-and-back direction and stacked on each other in a left-and-right direction; and
a bus bar assembly (<NUM>) configured to provide electric connection between the plurality of secondary batteries (<NUM>),
wherein the bus bar assembly (<NUM>) comprises:
a first insulating frame (<NUM>) where one or more insertion portions (H1) perforated from a back surface to a front surface are formed such that a plurality of electrode leads (<NUM>) are inserted and comprising an electric insulating material;
a second insulating frame (<NUM>) mounted on the front surface of the first insulating frame (<NUM>) and comprising an electric insulating material;
a first bus bar (<NUM>) mounted on the first insulating frame (<NUM>), contacting one of the plurality of electrode leads (<NUM>) inserted into each of the one or more insertion portions (H1), the one electrode lead (<NUM>) being located at one end of the plurality of electrode leads (<NUM>), and comprising an electric conductive material; and
a second bus bar (<NUM>) mounted on the second insulating frame (<NUM>), contacting one of the plurality of electrode leads (<NUM>) inserted into each of the one or more insertion portions (H1), which is located at the other end, and comprising an electric conductive material.