KR20220134305A - Battery apparatus integrated with electric component and Method for assembling the same - Google Patents

Abstract

Disclosed is a battery device integrated with electric components capable of securing a degree of freedom in arranging a space arrangement for battery system assembly (BSA) modules and/or electric components as a platform dedicated for an electric vehicle is developed. The battery device integrated with electric components comprises: a lower case; a battery module seated in the lower case and having a plurality of battery cells disposed thereon; an electric component integration module assembled on the upper surface of the battery module and electrically connecting a plurality of battery cells and a plurality of electric components; and an upper case assembled to the upper surface of the electric component integration module to be fastened to the lower case.

Description

Battery apparatus integrated with electric component and method for assembling the same

The present invention relates to a battery system, and more particularly, to an electronic component integrated battery device in which electrical components divided into several modules are integrated into one, and to a method of assembling the same.

Due to the structural limitations of the existing battery device for electric vehicles that have to be loaded in the internal combustion engine platform, it is difficult to efficiently configure the space of modules and electronic components constituting the battery system. In other words, the battery module may include various electronic components for controlling charging and discharging of battery cells, such as a battery management system (BMS), a relay, a current sensor, a fuse, and the like. The electrical component housing houses these various electrical components integrally.

As a result, the connection structure between modules and the arrangement of electronic components were not optimized, which was the biggest factor in the difficulty of applying process automation. In addition, a structurally robust design was required due to the nature of the battery pack to be additionally installed on the existing vehicle platform, which caused inefficiency in volumetric energy density.

Accordingly, in accordance with the trend of miniaturization of the battery module/pack, the size of the electronic device housing is also miniaturized.

In addition, as a dedicated platform for electric vehicles is developed, it is necessary to secure a degree of freedom in space arrangement of modules and/or electric components of a Battery System Assembly (BSA).

1. Korea Patent No. 10-1702505 (Registration Date: January 26, 2017)

The present invention has been proposed to solve the problems caused by the above background art, and as a dedicated platform for electric vehicles is developed, the module and/or electronic components of the BSA (Battery System Assembly) are integrated to secure a degree of freedom in the space arrangement of the electronic components. An object of the present invention is to provide a battery device and a method for assembling the same.

Another object of the present invention is to provide an electronic device integrated battery device capable of realizing an optimum volumetric energy density with a CTP (Cell To Pack) structure, and a method for assembling the same.

In addition, it is another object of the present invention to provide an electronic device integrated battery device capable of process automation and a method for assembling the same.

The present invention provides an electronic component integrated battery device capable of securing a degree of freedom in space arrangement of modules and/or electrical components of a BSA (Battery System Assembly) as a dedicated platform for an electric vehicle is developed in order to achieve the above object.

The electronic device integrated battery device,

lower case;

a battery module seated in the lower case and having a plurality of battery cells disposed therein;

an electrical component integration module assembled on the upper surface of the battery module and electrically connecting the plurality of battery cells and a plurality of electrical components; and

and an upper case assembled on the upper surface of the electrical component integration module and fastened to the lower case.

In addition, the electrical component integration module, a plurality of the electrical components; and

A frame body comprising a lattice part constituting a lattice in which an empty space is formed, a first fixing part integrally formed under the lattice part, and a second fixing part integrally formed on the upper part of the lattice part to fix a plurality of electrical components. It is characterized in that it includes.

In addition, the plurality of electrical equipment is characterized in that it is connected to an upper connection portion disposed at one end portion of the grid portion and a lower connection portion disposed at the other end portion of the grid portion.

In addition, the upper connection part and the lower connection part are respectively connected to a high voltage bus bar disposed above and below the battery module through a connection bus bar for connection with a fuse unit among the plurality of electrical components.

In addition, a plurality of intermediate connecting portions spaced apart from each other at regular intervals are disposed between the upper connecting portion and the lower connecting portion.

In addition, the plurality of the intermediate connecting portion is characterized in that it comprises a connecting bus bar assembly disposed between the end and the end of the battery cell.

In addition, the connecting bus bar assembly may include: a connecting member made of a metal material integral with the bus bar; a lower insulating cap fastened to the lower end of the connecting member; and an upper insulating cap fastened to the upper end of the connecting member.

In addition, a concave portion having a concave shape is formed at a distal end of the connecting member for fitting with the lower insulating cap and the upper insulating cap.

In addition, the connection member is characterized in that the polygonal shape so that the lead tabs between the plurality of battery cells are welded.

Also. A sensing tab is disposed on the upper portion of the upper insulating cap for connection of a connector type with the management unit among the plurality of electrical components, and the sensing tab is connected to the connection tab through wire bonding, and the connection tab is applied to the connector type It is characterized in that it is connected to the voltage sensing wire.

In addition, the upper connection part and the lower connection part may include: a plurality of sensing tabs disposed on top of the high voltage bus bar installed at the ends of the plurality of battery modules; a connection terminal connecting two of the plurality of sensing tabs; and a connection tab connected to the connection terminal by wire bonding.

In this case, the connection tab is characterized in that it is connected to a voltage sensing wire for connecting the management unit 250 and the plurality of sensing tabs in a connector type among the plurality of electronic devices.

On the other hand, another embodiment of the invention ball, (a) preparing a lower case; (b) seating a battery module in which a plurality of battery cells are disposed in the lower case; (c) assembling an electrical component integration module on an upper surface of the battery module, and electrically connecting the plurality of battery cells disposed in the battery module and a plurality of electrical components disposed in the electrical component integration module; and (d) assembling the upper case on the upper surface of the electrical component integration module and fastening the upper case to the lower case.

According to the present invention, the efficiency of volumetric energy density can be improved by optimizing the spatial structure.

In addition, as another effect of the present invention, it is possible to automate the wiring process, which has been done manually, with the integrated module structure of the electronic components.

1 is an exploded perspective view of a battery device according to an embodiment of the present invention.
FIG. 2 is a conceptual diagram illustrating the configuration of the integrated electronic module shown in FIG. 1 .
3 is a conceptual diagram illustrating the configuration of the battery module shown in FIG. 1 .
FIG. 4 is a partial perspective view illustrating a connection concept for voltage and temperature sensing through the integrated electronic module shown in FIG. 2 .
FIG. 5 is a perspective view of the connecting busbar assembly shown in FIG. 4 ;
FIG. 6 is a partial perspective view illustrating a connection concept for voltage sensing and bus bar connection through the integrated electronic module shown in FIG. 2 .
7 is a flowchart illustrating an assembly process of a battery device according to an embodiment of the present invention.

Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings so that those of ordinary skill in the art to which the present invention pertains can easily implement them. However, the present invention may be embodied in several different forms and is not limited to the embodiments described herein. And in order to clearly explain the present invention in the drawings, parts irrelevant to the description are omitted, and similar reference numerals are attached to similar parts throughout the specification.

In order to clearly express various layers and regions in the drawings, the thicknesses are enlarged. Throughout the specification, like reference numerals are assigned to similar parts. When a part of a layer, film, region, plate, etc. is said to be "on" another part, it includes not only the case where it is "directly on" another part, but also the case where there is another part in between. Conversely, when we say that a part is "just above" another part, we mean that there is no other part in the middle. Also, when it is said that a part is formed "whole" on another part, it means that it is formed not only on the entire surface (or front) of the other part, but also on a part of the edge.

Hereinafter, an electronic device integrated battery device and an assembly method thereof according to an embodiment of the present invention will be described in detail with reference to the accompanying drawings.

1 is an exploded perspective view of a battery device 100 according to an embodiment of the present invention. Referring to FIG. 1 , the battery device 100 includes a lower case 110 , a battery module 120 seated in the lower case 110 , and an electrical component integrated module that is assembled and electrically connected to the upper surface of the battery module 120 . 130 , may be configured to include an upper case 140 assembled on the upper surface of the electrical component integration module 130 and fastened to the lower case 110 .

The lower case 110 has an open top structure to accommodate the battery module 120 as a cooling-integrated case. In addition, the lower case 110 may be coupled to a heat sink for cooling. Of course, it is also possible to attach a thermal pad. It is also possible to apply thermal grease to the surface of the thermal pad.

Of course, it is also possible to use cooling channels. As a material of the lower case 110 , a non-metal such as aluminum or an aluminum alloy is used, but is not limited thereto, and reinforced plastic may be used. By using the reinforced plastic as a material, high strength, high rigidity, water resistance, and chemical resistance are excellent, and the weight itself can be reduced compared to the case of using aluminum as a material in the related art. As the reinforcing plastic, a fiber-reinforced plastic in which a thermosetting resin such as unsaturated polyester or an epoxy resin is reinforced with glass fibers can be used.

The battery module 120 is configured by disposing battery cells. The battery cells have a CTP (Cell To Pack) structure.

The electronic component integration module 130 is assembled on the upper surface of the battery module 120 and is electrically connected to the battery cell. Examples of electronic devices include a battery management system (BMS), a relay, a current sensor, and a fuse.

The upper case 140 covers the opening of the lower case 110 to form the exterior of the battery device 100 . The assembly of the lower case 110 and the upper case 140 uses a bolting method using a bolt and a nut, but is not limited thereto, and an adhesive or a welding method may be used. As the adhesive, silicone, epoxy, ethylene-vinyl acetate-based, polyolefin-based, styrene block copolymer-based, polyamide-based, polyester-based, or urethane-based adhesives may be used.

FIG. 2 is a schematic diagram of the configuration of the electronic component integration module 130 shown in FIG. 1 . Referring to FIG. 2 , the electrical component integration module 130 may include a frame body 210 and electrical components 240 and 250 disposed on the upper surface of the frame body 210 . The electrical components 240 and 250 may be the management unit 240 , the fuse unit 250 , and the like.

The frame body 210 includes a grid portion 213 constituting a grid in which the empty space 214 is formed, a second fixing portion 212 integrally formed on the upper portion of the grid portion 213 to fix an electric device, and a grid portion ( It consists of a first fixing part 211 integrally formed on the lower part of the 213 .

The lattice unit 213 is composed of a bar-shaped member having a vertical axis and a horizontal axis to form a rectangular space 214 . Of course, the rod-shaped member is also integrally formed with the frame body 210 .

The first fixing unit 211 may have an isosceles rectangular shape in order to mount and fix the management unit 240 , the fuse unit 250 , and the like, which are electrical components. The management unit 240 is connected to the battery module 120 to optimize the management of the battery module 120 to increase energy efficiency and extend the lifespan. It monitors battery voltage, current and temperature in real time and prevents excessive charging and discharging in advance, improving battery safety and reliability. For this purpose, a voltage sensor, a current sensor, a temperature sensor, etc. are configured.

The fuse unit 250 is composed of a fuse, a switching element, and the like, and performs a function of blocking power. In other words, when the fuse and the switching element are connected in series to generate an overcurrent, the fuse is blown to protect the battery module 120 . Of course, even if the fuse is not blown, the overcurrent may be secondarily blocked using the switching element.

A power relay is used as the switching element, but is not limited thereto, and semiconductor switching elements such as FET (Field Effect Transistor), MOSFET (Metal Oxide Semiconductor FET), IGBT (Insulated Gate Bipolar Mode Transistor), and power rectifying diode, thyristor, etc. , GTO (Gate Turn-Off) thyristor, TRIAC (Triode for alternating current), SCR (Silicon Controlled Rectifier), IC (Integrated Circuit) circuit and the like may be used. In particular, in the case of a semiconductor device, a bipolar device, a power MOSFET (Metal Oxide Silicon Field Effect Transistor) device, etc. may be used. The power MOSFET device has a double-diffused metal oxide semiconductor (DMOS) structure unlike general MOSFETs due to high voltage and high current operation.

At both ends of the grid unit 213, connection units 221 and 222 performing voltage sensing and bus bar functions are configured. The connecting portions 221 and 222 include an upper connecting portion 221 formed at an upper end of the grid portion 213 and a lower connecting portion 222 formed at a lower end of the grid portion 213 . The lower connection part 222 is connected to the high voltage bus bar 251 . Of course, the upper connection part 221 is also connected to the high voltage bus bar formed on the upper part of the battery module 120 . To this end, a connecting bus bar 260 is configured. The connection bus bar 260 is directly connected to the fuse unit 250 . Alternatively, the management unit 240 is connected in a connector manner, and the connector may be composed of a plurality of wires, and is covered for insulation.

The first to third intermediate connecting portions 231,232,233 are formed at regular intervals between the upper connecting portion 221 formed at the upper end of the grid portion 213 and the lower connecting portion 222 formed at the lower end of the grid portion 213. do. The first to third intermediate connectors 231,232 and 233 are connected between the battery cells to sense the voltage and/or temperature of the battery cells. Of course, the sensor is configured in the management unit 240, but may be configured between battery cells.

A fastening hole 201 is formed in the first fixing part 211 and the second fixing part 212 of the frame body 210 . The frame body 210 is coupled to the surface of the lower case 110 through the fastening hole 201 . Of course, the battery module 120 is placed between the frame body 210 and the lower case 110 . In FIG. 2 , three intermediate connections are illustrated, but the present invention is not limited thereto, and may be less than three or more than three.

The frame body 210 may be made of reinforced plastic made of an insulating material.

FIG. 3 is a conceptual diagram illustrating the configuration of the battery module 120 shown in FIG. 1 . Referring to FIG. 3 , in the battery module 120 , battery cells 310 are connected in series and/or in parallel. The battery cells 310 may be a high voltage battery cell for an electric vehicle, such as a nickel metal battery cell, a lithium ion battery cell, a lithium polymer battery cell, a lithium sulfur battery cell, a sodium sulfur battery cell, or an all-solid-state battery cell. In general, a high voltage battery is a battery used as a power source for moving an electric vehicle, and refers to a high voltage of 100V or more. However, the present invention is not limited thereto, and a low-voltage battery is also possible. In FIG. 3 , the battery module 120 is configured by a pouch-shaped battery cell 310 , but the battery module 120 may also be configured in a CTP (Cell To Pack) structure. The CTP structure refers to a structure in which a pack is made directly from battery cells. Accordingly, the module can be completed only with battery cells except for other structures in the battery module 120 .

In addition, in FIG. 3 , a plurality of battery cells 310 are connected in series and are connected in parallel. Of course, it is also possible to connect only in series, and it is also possible to connect only in parallel.

Lead tabs 340 are formed at both ends of the battery cell 310 . In other words, the + pole lead tab 330 and the - pole lead tab 340 are connected by the connection bus bar assembly 320 .

FIG. 4 is a partial perspective view illustrating a connection concept for sensing voltage and temperature through the electronic component integration module 130 shown in FIG. 2 . Referring to FIG. 4 , a connection bus bar assembly 320 is disposed between the distal end and the distal end of the battery cell 310 . The sensing tab 430 at the upper end of the connection bus bar assembly 320 is connected to the connection tab 410 through wire bonding 410 . The connection tab 410 is connected to a voltage sensing wire 440 for voltage sensing. The voltage sensing wire 440 is covered for insulation, the voltage sensing wire 440 is connected to a connector (not shown), and the connector is connected to the management unit 240 . The connection tab 410 is a rectangular plate piece made of a metal material. Accordingly, it may be copper, bronze, brass, alloys thereof, or the like. Of course, a material using gold plating on a non-metal may also be used.

FIG. 5 is a perspective view of the connecting bus bar assembly 320 shown in FIG. 4 . Referring to FIG. 5 , the connecting bus bar assembly 320 includes a connecting member 510 made of a metal, a lower insulating cap 522 fastened to the lower end of the connecting member 510 , and an upper end of the connecting member 510 . It is configured to include an upper insulating cap 521 and the like. The lower insulating cap 522 has one end open and the other end closed, and the upper insulating cap 521 has one end open so that the upper end of the connecting member 510 protrudes, and the other end is also open. In particular, the sensing tab 430 is formed on the upper insulating cap 521 to be in contact with other circuit terminals.

The connecting member 510 may have a hollow shape. Also, the connecting member 510 may have a central cross-section of a rectangle or a polygonal shape such as a hexagon. In addition, the connecting member 510 may be made of a metallic material, such as conductive copper, brass, bronze, aluminum alloy, or the like.

The lower insulating cap 522 has a large bottom area and a narrow top area. The distal end of the connecting member 510 is assembled into this recessed portion tightly. To this end, the lower insulating cap 522 has a stepped structure. For this fitting, a concave portion having a central cross-section concave shape is formed at the distal end of the connecting member 510 . Of course, it may be configured in reverse. That is, a recess may be formed in the center of the upper end of the lower insulating cap 522 . It is also possible to apply an adhesive to the inside of the recess for stable fixation.

Similarly to the lower insulating cap 522 , the upper insulating cap 521 is formed to have a wide bottom area and a narrow top area. Of course, in FIG. 5, it has an inverted shape. In addition, assembling grooves 501 are formed on both sides of the upper insulating cap 521 . The end of the connecting member 510 is inserted into this assembly groove. Of course, a concave portion having a central cross-section concave shape is formed at the distal end of the connecting member 510 . There is almost no step difference in the upper insulating cap 521, and the upper end side of the recess formed at the end of the connecting member 510 is larger than the lower end side.

In addition, the lower insulating cap 321 and the upper insulating cap 322 are made of an injection insulator. Accordingly, as a material of the lower insulating cap 321 and the upper insulating cap 322 , a thermosetting resin may be mainly used, but the present invention is not limited thereto, and engineering plastics may be used.

The lead tabs 340 and 330 of the battery cell 310 are welded to the outer surface of the connecting member 510 made of a metal material that is integral with the bus bar. Of course, welding is also performed between the lead tabs 340 and 330 .

FIG. 6 is a partial perspective view illustrating a connection concept for voltage sensing and bus bar connection through the electronic component integration module 130 shown in FIG. 2 . Referring to FIG. 6 , a high voltage bus bar 251 serving voltage sensing and bus bar functions is installed at the distal end of the battery module 120 . The high voltage bus bar 251 is exposed to the outside, and a rod made of a conductive material is formed inside the high voltage bus bar 251 . Accordingly, a sensing tab 640 is installed on the upper side, and the sensing tab 640 is connected to a sensing tab of another high voltage bus bar by a connection terminal 620 . Of course, the sensing tap is also connected to the connection bus bar 260 .

In addition, the sensing tab 640 is connected to the voltage sensing wire 631 by the connection tab 630 . The sensing tab 640 is connected to the connection tab 630 by wire bonding 621 .

A fastening hole 601 is formed for fixing the high voltage bus bar 251 . A long bolt is inserted into this fastening hole 601 and fixed by fastening with a nut.

7 is a process diagram illustrating an assembly process of the battery device 100 according to an embodiment of the present invention. Referring to FIG. 7 , the battery module 120 is first assembled (step S710 ).

Thereafter, the electrical component integration module 130 is assembled, the electrical component integration module 130 is assembled on the surface of the battery module 120 , and wire bonding is performed for electrical connection (step S730 ).

Thereafter, the upper case 140 is fastened to the lower case 110 (step S740).

100: battery device
110: lower case
120: upper case
210: frame body
211: first fixing part 212: second fixing part
213: grid unit
221: upper connection 222: lower connection
231,232,233: first to third intermediate connections
310: battery cell
320: connecting busbar assembly
330,340: lead tab
420,621: wire bonding
410,630: Connection tab
430,640: sensing tab
440,631: voltage sensing wire

Claims (12)

lower case 110;
a battery module 120 seated in the lower case 110 and having a plurality of battery cells 310 disposed therein;
an electrical component integration module 130 assembled on the upper surface of the battery module 120 and electrically connecting the plurality of battery cells 310 and the plurality of electrical components 240 and 250; and
an upper case 140 assembled on the upper surface of the electrical component integration module 130 and fastened to the lower case 110;
Electrical components integrated battery device comprising a.
The method of claim 1,
The electrical component integration module 130,
a plurality of the electrical components 240 and 250; and
The grid portion 213 constituting the grid in which the empty space 214 is formed, the first fixing portion 211 integrally formed under the grid portion 213 , and the upper portion of the grid portion 213 integrally formed The integrated battery device for electrical components, characterized in that it comprises a frame body (210) formed of a second fixing part (212) for fixing a plurality of electrical components (240,250).
3. The method of claim 2,
The plurality of electrical devices 240 and 250 are connected to an upper connection part 221 disposed on one end of the grid part 213 and a lower connection part 222 disposed on the other end of the grid part 213. An electronic integrated battery device.
4. The method of claim 3,
The upper connection part 221 and the lower connection part 222 are connected to the upper and lower portions of the battery module 120 through a connection bus bar 260 for connection with the fuse unit 250 among the plurality of electrical components 240 and 250 . An integrated battery device for electrical components, characterized in that each is connected to the arranged high voltage bus bar (251).
4. The method of claim 3,
A plurality of intermediate connecting portions (231,232,233) spaced apart from each other at regular intervals are disposed between the upper connecting portion (221) and the lower connecting portion (222).
6. The method of claim 5,
The plurality of intermediate connecting portions (231,232,233) comprises a connecting bus bar assembly (320) disposed between the distal end and the distal end of the battery cell (310).
7. The method of claim 6,
The connection bus bar assembly 320 includes:
a bus bar-integrated metal connecting member 510;
a lower insulating cap 522 fastened to the lower end of the connecting member 510; and
and an upper insulating cap (521) fastened to an upper end of the connecting member (510).
8. The method of claim 7,
An integrated battery device for electrical components, characterized in that a recess having a concave shape is formed at a distal end of the connection member (510) for fitting with the lower insulating cap (522) and the upper insulating cap (521).
8. The method of claim 7,
The connecting member 510 has a polygonal shape so that the lead tabs 330 and 340 between the plurality of battery cells 310 are welded.
8. The method of claim 7,
A sensing tab 430 is disposed on the upper portion of the upper insulating cap 521 for connector type connection with the management unit 250 among the plurality of electrical components 240 and 250 , and the sensing tab 430 is wire bonding 410 . is connected to the connection tab 420 through the , and the connection tab 420 is connected to the voltage sensing wire 440 applied to the connector method.
5. The method of claim 4,
The upper connection part 221 and the lower connection part 222 are,
a plurality of sensing tabs 640 disposed on top of the high voltage bus bar 251 installed at the ends of the plurality of battery modules 120;
a connection terminal 620 for connecting two of the plurality of sensing tabs 640; and
and a connection tab 630 connected to the connection terminal 620 and wire bonding 621.
The connection tab 630 is connected to a voltage sensing wire 631 for connecting the management unit 250 and the plurality of sensing tabs 640 among the plurality of electrical components 240 and 250 in a connector type. battery device.
(a) preparing the lower case 110;
(b) seating the battery module 120 in which a plurality of battery cells 310 are disposed in the lower case 110;
(c) assembling the electrical component integration module 130 on the upper surface of the battery module 120, and disposed in the plurality of battery cells 310 and the electrical component integration module 130 disposed in the battery module 120 electrically connecting a plurality of electrical devices 240 and 250 to be used; and
(d) assembling the upper case 140 on the upper surface of the electrical component integration module 130 and fastening it with the lower case 110;
Method of assembling an integrated electronic battery device comprising a.

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