SECONDARY BATTERY AND METHOD FOR MANUFACTURING THE SAME

DETAILED DESCRIPTION OF THE INVENTION

1. Technical Field

Aspects of the present invention relate to a secondary battery and a method for manufacturing the same.

2. Background Art

Recently, the use of portable electronic devices has increased with the rapid development of communication and computer industries. Rechargeable secondary batteries are widely used as power sources of portable electronic devices.

A secondary battery includes an electrode assembly and a pouch, the electrode assembly including a first electrode, a second electrode, and a separator disposed between the first electrode and the second electrode and insulating the first electrode and the second electrode from each other.

In the electrode assembly, it is quite an important challenge to maintain proper alignment of the first electrode and the second electrode. To address the alignment issue, additional apparatuses or methods have conventionally been used.

Technical Problems

Aspects of the present invention provide a secondary battery, which can easily achieve alignment of a first electrode and a second electrode, and a method for manufacturing the same.

Aspects of the present invention also provide a secondary battery, in which an electrode assembly including a first electrode, a second electrode, and a separator can be easily assembled with a pouch, and a method for manufacturing the same.

Aspects of the present invention further provide a secondary battery, in which an electrode assembly including a first electrode, a second electrode, and a separator can be easily assembled with a double-cavity pouch, and a method for manufacturing the same.

Technical Solutions

At least one of the above and other features and advantages may be realized by providing a secondary battery including an electrode assembly and a pouch, the electrode assembly including a first electrode, a second electrode, and a separator disposed between the first electrode and the second electrode and insulating the first electrode and the second electrode from each other, the pouch configured to have a bottom face and lateral faces extending from edges of the bottom face and including a cavity to accommodate the electrode assembly, wherein the pouch includes at least one alignment protrusion provided on its lateral face, and the electrode assembly includes at least one alignment hole provided at its edge, the at least one alignment hole corresponding to the alignment protrusion of the pouch.

At least one of the above and other features and advantages may be realized by providing a method for manufacturing a secondary battery, the method including: preparing a pouch having a cavity, the pouch including at least one alignment protrusion protruding toward the cavity, preparing a first electrode including at least one alignment hole corresponding to the at least one alignment protrusion, a second electrode and a separator, stacking the first electrode, the second electrode with the separator disposed between the first electrode and the second electrode, wherein the stacking of the first electrode, the separator and the second electrode is performed by the at least one alignment protrusion and the at least one alignment hole; and sealing the pouch.

ADVANTAGEOUS EFFECTS

According to the embodiments, alignment of a first electrode and a second electrode can be easily achieved.

In addition, an electrode assembly including a first electrode, a second electrode, and a separator can be easily assembled with a pouch.

Further, an electrode assembly including a first electrode, a second electrode, and a separator can be easily assembled with a pouch having a double-layered structure.

DETAILED DESCRIPTION FOR CARRYING OUT THE INVENTION

Example embodiments will now be described more fully hereinafter with reference to the accompanying drawings.

FIGS. 1A through 1F illustrate a secondary battery according to an embodiment of the present invention, in which FIG. 1A is an exploded perspective view illustrating a secondary battery according to an embodiment of the present invention, FIG. 1B illustrates a pouch as one of component members of the secondary battery shown in FIG. 1A, FIG. 1C illustrates a stack of an electrode assembly of the secondary battery shown in FIG. 1A, and FIGS. 1D through 1F illustrate stacked structures of the electrode assembly as one of component members of the secondary battery shown in FIG. 1A, in which a first electrode, a second electrode and a separator are stacked.

Referring to FIGS. 1A through 1F, the secondary battery 100 includes the pouch 110 and an electrode assembly 120.

The pouch 110 includes at least one alignment protrusion 130, and the electrode assembly 120 includes at least one alignment hole 140.

In addition, the secondary battery 100 includes a protective circuit module 150.

The pouch 110 includes a main body 112 and a cover 114.

The main body 112 includes a cavity 116, that is, a space to accommodate the electrode assembly 120.

The main body 112 has a bottom face 112a and a lateral face 112b extending from the bottom face 112a shaped of a rectangle, and the cavity 116 is provided in a space formed by the bottom face 112a and the lateral face 112b.

Referring to FIG. 1A, the cavity 116 has a hexagonal shape, including the bottom face 112a shaped of a rectangle, the lateral face 112b consisting of four planes, and four corners formed by each two adjacent ones of the four planes of the lateral face 112b.

In addition, the main body 112 has an entrance of the cavity 116, that is, a sealing part 112c extending from the lateral face 112b.

The cover 114 extends from a predetermined edge of the sealing part 112c of the main body 112.

The cover 114 is hermetically sealed with the sealing part 112c of the main body 112 while covering the cavity 116, thereby sealing the secondary battery 100. Thus, the cover 114 includes a covering part 114a corresponding to the cavity 114a and a sealing part 114b corresponding to the sealing part 112c of the main body 112.

The pouch 110 preferably has a high strength. As shown in FIG. 1A, the pouch 110 may have a three-layered structure, including an intermediate layer 118a and outer layers 118b and 118c. Here, the intermediate layer 118a is preferably a film made of a metal, such as aluminum (Al) or copper (Cu), and the outer layers 118b and 118c are preferably insulating layers, for example, a polymeric or ceramic layers.

A thickness of aluminum (Al) used in the intermediate layer 118a is preferably approximately 50 μm or greater, and a thickness of copper (Cu) used in the intermediate layer 118a is preferably approximately 20 μm or greater.

The pouch 110 includes at least one alignment protrusion 130 on the lateral face 112b of the cavity 116.

Although FIG. 1B illustrates that the at least one alignment protrusion 130 is provided at the corner of the lateral face 112b, the invention is not limited to the illustrated example and the alignment protrusion 130 may be provided at any location of the lateral face 112b. In addition, FIG. 1B illustrates that the alignment protrusion 130 has a central angle of 90 degrees in view of a horizontal section, as indicated by a fan-shaped hatching region labeled 132 in FIG. 1B, but the invention is not limited thereto.

As described above, the electrode assembly 120 includes the first electrode 121, the second electrode 122 and the separator 123 insulating the first electrode 121 and the second electrode 122 from each other by interposing into a contacting portion of the first electrode 121 and the second electrode 122.

In the electrode assembly 120, the first electrodes 121 and the second electrodes 122 are repeatedly stacked to sandwich each of the separators 123 therebetween.

Each of the first electrodes 121 includes a first electrode coating portion provided on at least one surface thereof, and each of the second electrodes 122 includes a second electrode coating portion provided on at least one surface thereof.

Here, the first electrodes 121 are positive electrodes and the second electrodes 122 are negative electrodes. Conversely, the first electrodes 121 may be negative electrodes and the second electrodes 122 may be positive electrodes.

The electrode assembly 120 includes first electrode tabs 124 extending from the respective first electrodes 121 and second electrode tabs 125 extending from the respective second electrodes 122. In addition, the electrode assembly 120 includes a first electrode lead 126 connected to the respective first electrode tabs 124 and a second electrode lead 127 connected to the respective second electrode tabs 125.

An insulating tape 128 is provided at each predetermined area of the first electrode lead 126 and the second electrode lead 127, respectively, thereby preventing the first electrode lead 126 and the second electrode lead 127 from being damaged when sealing the pouch 110 while insulating the first and second electrode lead 126 and 127 from the pouch 110.

The electrode assembly 120 includes at least one alignment hole 140 formed at its edge, the at least one alignment hole 140 corresponding to the alignment protrusion 130 of the pouch 110.

As shown in FIG. 1C, the alignment hole 140 is formed to have a horizontal section shaped of an arc directed inward with respect to the electrode assembly 120. Here, the shape of arc of the alignment hole 140 is preferably substantially the same as that of fan 132 of the alignment protrusion 130, which corresponds to the hatching region 132 in FIG. 1C.

The alignment hole 140, which is formed in at least one of the component members of the electrode assembly 120, that is, the first electrode 121, the second electrode 122 and the separator 123, preferably in each of the first electrode 121, the second electrode 122 and the separator 123, facilitates proper alignment of the first electrode 121, the second electrode 122 and the separator 123 when the first electrode 121, the second electrode 122 and the separator 123 are accommodated in the cavity 116 of the pouch 110.

Here, the electrode assembly 120 having the alignment hole 140 may be configured in various manners, as labeled 120a, 120b and 120c in FIGS. 1D through 1F.

The electrode assembly 120a shown in FIG. 1D has a stacked structure in which a first electrode 121a, a separator 123a and a second electrode 122a are stacked.

Here, the electrode assembly 120a is configured such that a size of the separator 123a is greater than that of either of the first electrode 121a and the second electrode 122a. Preferably, the separator 123a is largest in size, the second electrode 122a is middle-sized and the first electrode 121a is smallest in size. This holds true when the first electrode 121a is a positive electrode and the second electrode 122a is a negative electrode. In a reversed case, that is, when the first electrode 121a is a negative electrode and the second electrode 122a is a positive electrode, the electrode assembly 120a may be configured such that the first electrode 121a is larger than the second electrode 122a.

An alignment hole 140a is formed in each of the first electrode 121a, the separator 123a and the second electrode 122a, respectively. Thus, when the electrode assembly 120a, specifically, each of component members of the electrode assembly 120a including the first electrode 121a, the separator 123a and the second electrode 122a is accommodated in the cavity 116, the alignment hole 140a facilitates proper alignment of the component members of the electrode assembly 120a.

Accordingly, the electrode assembly 120a shown in FIG. 1D has a layered structure in which the first electrode 121a and the second electrode 122a are stacked with the separator 123a that is largest in size, thereby achieving an ensured effect of insulating the first electrode 121a and the second electrode 122a from each other by the separator 123a.

In addition, since the separator 123a is largest in size and the first electrode 121a and the second electrode 122a are relatively smaller than the separator 123a, the first electrode 121a and the second electrode 122a are opposed to each other with the separator 123a interposed therebetween.

Here, if the first electrode 121a is smaller than the second electrode 122a, the first electrode 121a and the second electrode 122a are aligned such that the entire area of the first electrode 121a is opposed to part of the second electrode 122a, as indicated by dotted lines on the separator 123a shown in FIG. 1D.

If the electrode assembly 120 has the stacked structure, like the electrode assembly 120a shown in FIG. 1D, the contour of the electrode assembly 120 shown in FIG. 1C may correspond to that of the separator 123a, and the contour of the alignment hole 140 may also correspond to that of the alignment hole 140a of the separator 140a.

The electrode assembly 120b shown in FIG. 1E has a stacked structure in which an insulating-layer separator 123b is provided on an entire surface of a first electrode 121b or a second electrode 122b, and the first electrode 121b and the second electrode 122b having the insulating-layer separator 123b are repeatedly stacked.

Therefore, the electrode assembly 120b shown in FIG. 1E includes the insulating-layer separator 123b, rather than the separator 123a shown in FIG. 1D, the insulating-layer separator 123b provided on the first electrode 121b or the second electrode 122b and performing the same function as the separator 123a shown in FIG. 1D. That is to say, the insulating-layer separator 123b insulates the first electrode 121b and the second electrode 122b from each other.

Although FIG. 1E illustrates that the insulating-layer separator 123b is provided on both of the first electrode 121b and the second electrode 122b, the invention is not limited thereto. However, the insulating-layer separator 123b may be provided on only one of the first electrode 121b and the second electrode 122b, if necessary.

In addition, FIG. 1E illustrates that the insulating-layer separator 123b is provided on a portion of each of the first electrode tab 124 and the second electrode tab 125. In the first electrode tab 124 and the second electrode tab 125 shown in FIG. 1E, portions without the insulating-layer separator 123b are provided to be connected with first and second electrode lead 126 and 127.

An alignment hole 140b is formed in each of the first electrode 121b and the second electrode 122b, respectively. Thus, when the electrode assembly 120b, specifically, each of component members of the electrode assembly 121b including the first electrode 121b and the second electrode 122b is accommodated in the cavity 116, the alignment hole 140b facilitates proper alignment.

Accordingly, the electrode assembly 120b shown in FIG. 1E has a layered structure in which the first electrode 121b and the second electrode 122b are stacked with the insulating-layer separator 123b, thereby achieving an ensured effect of insulating the first electrode 121b and the second electrode 122b from each other by the insulating-layer separator 123b provided on the first electrode 121b and the second electrode 122b.

If the electrode assembly 120 has the stacked structure, like the electrode assembly 120b shown in FIG. 1E, the contour of the electrode assembly 120 shown in FIG. 1C may correspond to that of the insulating-layer separator 123b, and the contour of the alignment hole 140 may also correspond to that of the alignment hole 140b of the insulating-layer separator 123b.

The electrode assembly 120c shown in FIG. 1F has a stacked structure in which a first electrode 121c or a second electrode 122c are insulated from the exterior of the electrode assembly 120c by two sheets of separators 123c, and the first electrode 121c and the second electrode 122c are repeatedly stacked.

Although FIG. 1F illustrates that the first electrode 121c is insulated from the exterior of the electrode assembly 120c by two sheets of separators 123c, the invention is not limited thereto. If necessary, the second electrode 122c may be insulated from the exterior of the electrode assembly 120c. Alternatively, both of the first electrode 121c and the second electrode 122c may be insulated from the exterior of the electrode assembly 120c.

Here, the insulating of the first electrode 121c or the second electrode 122c may be performed by fusing edges of the two sheets of separators 123c in a state in which the first electrode 121c or the second electrode 122c are placed between the two sheets of separators 123c. The fusing of the edges of the two sheets of separators 123c is performed by ultrasonic fusion or thermal fusion.

Referring to FIG. 1F, the first electrode 121c fused with the two sheets of separators 123c and the second electrode 122c are formed to have the same size. The reason of the foregoing is to facilitate proper alignment when the first electrode 121c fused with the two sheets of separators 123c is aligned with the second electrode 122c by the alignment protrusion 130 of the cavity 116.

Meanwhile, an alignment hole 140c is formed in each of the first electrode 121c fused with the two sheets of separators 123c and the second electrode 122c, respectively. Thus, when the electrode assembly 120c, specifically, each of component members of the electrode assembly 120c including the first electrode 121c fused with the two sheets of separators 123c and the second electrode 122c is accommodated in the cavity 116, the alignment hole 140c facilitates proper alignment of the component members of the electrode assembly 120c.

Accordingly, the electrode assembly 120c shown in FIG. 1F has a layered structure in which the first electrode 121c and the second electrode 122c with the two sheets of separators 123c are repeatedly stacked, thereby achieving an ensured effect of insulating the first electrode 121c and the second electrode 122c from each other by the two sheets of separators 123c.

If the electrode assembly 120 has the stacked structure, like the electrode assembly 120c shown in FIG. 1F, the contour of the electrode assembly 120 shown in FIG. 1C may correspond to that of the separator 123c or the first electrode 121c without the separator 123c fused thereto, and the contour of the alignment hole 140 may also correspond to that of the alignment hole 140c of the two sheets of separators 123c or the first electrode 121c or the second electrode 122c without the separator 123c fused thereto.

The protective circuit module 150 controls various operations of the secondary battery 100 as well as charge and discharge operations of the electrode assembly 120.

The protective circuit module 150 includes control devices 152, such as IC devices, and so forth, to prevent an over-current from flowing through the secondary battery 100.

In addition, the protective circuit module 150 includes external terminals 154 connecting the secondary battery 100 to external circuitry.

Although FIG. 1A illustrates that the control devices 152 and the external terminals 154 are provided on the same plane of the protective circuit module 150, the present invention is not limited thereto. In an alternative embodiment, the control devices 152 and the external terminals 154 may be provided on different planes of the protective circuit module 150.

The protective circuit module 150 is electrically connected to the first electrode lead 126 and the second electrode lead 127.

Therefore, in the secondary battery 100 according to an embodiment of the present invention, since the pouch 110 includes at least one alignment protrusion 130 on a lateral face 112b of the main body 112, and the electrode assembly 120 includes at least one alignment hole 140 at its edge, the at least one alignment hole 140 corresponding to the alignment protrusion 130, alignment of the first electrode 121, the second electrode 122 and the separator 123 of the electrode assembly 120 can be easily achieved.

FIGS. 2A and 2B illustrate a pouch and an electrode assembly as component members of a secondary battery according to another embodiment of the present invention. In the current embodiment, the pouch and the electrode assembly are shown in separate drawings, which is, however, for a better understanding of the invention, it is to be understood that the pouch and the electrode assembly are assembled with the secondary battery (100 of FIG. 1A) in actuality.

Referring to FIGS. 2A and 2B, the secondary battery according to another embodiment of the present invention includes the pouch 210 and an electrode assembly 220.

The pouch 210 includes a plurality of alignment protrusions 230 each having a fan-shape 232 (hatching regions in FIGS. 2A and 2B), and the electrode assembly 220 includes a plurality of alignment holes 240.

In addition, the secondary battery includes a protective circuit module 250.

The pouch 210 includes a main body 212 and a cover 214.

In the pouch 210, the main body 212 and the cover 214 correspond to the main body 112 and the cover 114, respectively, which have previously been described with reference to FIGS. 1A through 1C, and each of the plurality of alignment protrusions 230 corresponds to the alignment protrusion 130, which has previously been described with reference to FIG. 1B. Accordingly, a detailed description of these elements will not be given herein.

The electrode assembly 220 includes a first electrode (not shown), a second electrode (not shown), a separator (not shown), a first electrode tab 224, a second electrode tab 225, a first electrode lead 226, a second electrode lead 227 and an insulating tape 228, and these elements correspond to the first electrode 121, the second electrode 122, the separator 123, the first electrode tab 124, the second electrode tab 125, the first electrode lead 126, the second electrode lead 127 and the insulating tape 128, respectively, which have previously been described with reference to FIGS. 1A through 1C. Accordingly, a detailed description of these elements will not be given herein.

The electrode assembly 220 includes a first electrode tab 224 and a second electrode tab 225 which extend from one lateral face of the electrode assembly 220.

Since the electrode assembly 220 includes at least one stack of a first electrode (not shown) and a second electrode (not shown), a plurality of first electrode tabs 224 and a plurality of second electrode tabs 225 are provided in the electrode assembly 220 accordingly. In addition, the electrode assembly 220 includes a first electrode lead 226 connected to the respective first electrode tabs 224 and the second electrode lead 227 connected to the respective second electrode tabs 225.

Here, some of the first electrode tabs 224 and the second electrode tabs 225 connected to the first and second electrode lead 226 and 227 are accommodated in a tab accommodating space 260 between one face of the electrode assembly 220 and the main body 212.

The tab accommodating space 260 is provided by making a width of the electrode assembly 220 smaller than that of a cavity 216.

The tab accommodating space 260 may be selected among the alignment holes 240 provided in the tab accommodating space 260, specifically alignment holes positioned on one face of the electrode assembly 220, the alignment holes each having a smaller arc length than that of each of the alignment holes 240 positioned on the other face of the electrode assembly 220.

Therefore, the electrode assembly 220 has one face that is not brought into contact with a lateral surface of the main body 212 and the other face that is brought into contact with the lateral face of the main body 212, the one face being a face from which the first electrode tabs 224 and the second electrode tabs 225 extend, and the other face not being a face from which the first electrode tabs 224 and the second electrode tabs 225 extend which the first electrode tabs 224 and the second electrode tabs 225 extend.

The protective circuit module 250 includes control devices 252 and external terminals 254. The protective circuit module 250 are substantially the same as the protective circuit module 150 including the control devices 152 and the external terminals 154, as described above with reference to FIG. 1C. Accordingly, a detailed description of these elements will not be given herein.

FIGS. 3A and 3B illustrate a pouch and an electrode assembly as component members of a secondary battery according to still another embodiment of the present invention. In the current embodiment, the pouch and the electrode assembly are shown in separate drawings, which is, however, for a better understanding of the invention, it is to be understood that the pouch and the electrode assembly are assembled with the secondary battery (100 of FIG. 1A) in actuality.

Referring to FIGS. 3A and 3B, the secondary battery according to still another embodiment of the present invention includes the pouch 310 and an electrode assembly 320.

The pouch 310 includes a plurality of alignment protrusions 330 each having a fan-shape 332 (hatching regions in FIGS. 3A and 3B), and the electrode assembly 320 includes a plurality of alignment holes 340.

In addition, the secondary battery includes a protective circuit module 350.

The pouch 310 includes a main body 312 and a cover 314.

In the pouch 310, the main body 312 and the cover 314 correspond to the main body 112 and the cover 114, respectively, which have previously been described with reference to FIGS. 1A through 1C, and each of the plurality of alignment protrusions 330 corresponds to the alignment protrusion 130, which has previously been described with reference to FIG. 1B. Accordingly, a detailed description of these elements will not be given herein.

The electrode assembly 320 includes a first electrode (not shown), a second electrode (not shown), a separator (not shown), a first electrode tab 324, a second electrode tab 325, a first electrode lead 326, a second electrode lead 327 and an insulating tape 328, and these elements correspond to the first electrode 121, the second electrode 122, the separator 123, the first electrode tab 124, the second electrode tab 125, the first electrode lead 126, the second electrode lead 127 and the insulating tape 128, respectively, which have previously been described with reference to FIGS. 1A through 1C. Accordingly, a detailed description of these elements will not be given herein.

The electrode assembly 320 includes a first electrode tab 324 and a second electrode tab 325 which extend from one lateral face of the electrode assembly 320.

Since the electrode assembly 320 includes at least one stack of a first electrode (not shown) and a second electrode (not shown), each of the first electrode tab and the second electrode tab provided in the electrode assembly 320 may include a plurality of first electrode tabs and a plurality of second electrode tabs accordingly. In addition, the electrode assembly 320 includes a first electrode lead 326 connected to the respective first electrode tabs 324 and the second electrode lead 327 connected to the respective second electrode tabs 325.

Here, some of the first electrode tabs 324 and the second electrode tabs 325 connected to the first and second electrode lead 326 and 327 are accommodated in the cavity 316.

The electrode assembly 320 includes tab grooves 360 at its one face to accommodate some of the first electrode tabs 324 and the second electrode tabs 325, the one face being a face from which the first electrode tabs 324 and the second electrode tabs 325 extend.

In other words, the tab grooves 360 are included in each of first electrodes and second electrodes constituting the electrode assembly 320, and the first electrode tabs 324 and the second electrode tabs 325 extend from the tab grooves 360, so that some of the first electrode tabs 324 and the second electrode tabs 325 are accommodated in the tab grooves 360.

The protective circuit module 350 includes control devices 352 and external terminals 354. The protective circuit module 350 are substantially the same as the protective circuit module 150 including the control devices 152 and the external terminals 154, as described above with reference to FIG. 1C. Accordingly, a detailed description of these elements will not be given herein.

FIG. 4 illustrates a secondary battery according to still another embodiment of the present invention.

Referring to FIGS. 4A and 4B, the secondary battery according to still another embodiment of the present invention includes the pouch 410 and an electrode assembly 420.

The pouch 410 includes a plurality of alignment protrusions 430 each having a fan-shape 432 (hatching regions in FIGS. 4A and 4B), and the electrode assembly 420 includes a plurality of alignment holes 440.

In addition, the secondary battery includes a protective circuit module 450.

The pouch 410 includes a main body 412 including a bottom face 412a, lateral faces 412b and a sealing part 412c. The pouch 410 also includes a lid area and a cover 414.

In the pouch 410, the main body 412 and the cover 414 correspond to the main body 112 and the cover 114, respectively, which have previously been described with reference to FIGS. 1A through 1C, and each of the plurality of alignment protrusions 430 corresponds to the alignment protrusion 130, which has previously been described with reference to FIG. 1B. Accordingly, a detailed description of these elements will not be given herein.

The electrode assembly 420 includes a first electrode 421, a second electrode 422, a separator 423, a first electrode tab 424, a second electrode tab 425, a first electrode lead 426, a second electrode lead 427 and an insulating tape 428, and these elements correspond to the first electrode 121, the second electrode 122, the separator 123, the first electrode tab 124, the second electrode tab 125, the first electrode lead 126, the second electrode lead 127 and the insulating tape 128, respectively, which have previously been described with reference to FIGS. 1A through 1C. Accordingly, a detailed description of these elements will not be given herein.

The electrode assembly 420 includes a first electrode tab 424 and a second electrode tab 425 which extend from one lateral face of the electrode assembly 420.

Since the electrode assembly 420 includes at least one stack of the first electrode 421 and the second electrode 422, each of the first electrode tab 424 and the second electrode tab 425 provided in the electrode assembly 420 include a plurality of first electrode tabs and a plurality of second electrode tabs accordingly. The plurality of first electrode tabs 424 and the plurality of second electrode tabs 425 are connected to a first electrode lead 426 and a second electrode lead 427, respectively.

Here, some of the first electrode tabs 424 and the second electrode tabs 425 connected to the first and second electrode lead 426 and 427 are accommodated in a first tab cavity 462 and a second tab cavity 464, respectively.

The first tab cavity 462 is formed such that among the lateral faces 412b of the main body 412, a lateral face 412b1 corresponding to the first electrode tab 424 of the electrode assembly 420 is made to protrude outward.

The second tab cavity 464 is formed such that among the lateral faces 412b of the main body 412, a lateral face 412b2 corresponding to the second electrode tab 425 of the electrode assembly 420 is made to protrude outward.

The first and second tab cavities 462 and 464 are spaces from the cavity 416 that is enlarged such that portions of the lateral faces 412 protrude outward.

The protective circuit module 450 includes control devices 452 and external terminals 454. The protective circuit module 450 are substantially the same as the protective circuit module 150 including the control devices 152 and the external terminals 154, as described above with reference to FIG. 1C. Accordingly, a detailed description of these elements will not be given herein.

FIGS. 5A and 5B illustrate a pouch and an electrode assembly as component members of a secondary battery according to still another embodiment of the present invention. In the current embodiment, the pouch and the electrode assembly are shown in separate drawings, which is, however, for a better understanding of the invention, it is to be understood that the pouch and the electrode assembly are assembled with the secondary battery (100 of FIG. 1A) in actuality.

Referring to FIGS. 5A and 5B, the secondary battery according to still another embodiment of the present invention includes the pouch 510 and an electrode assembly 520.

In addition, the secondary battery includes a protective circuit module 550.

The pouch 510 includes a main body 512 and a cover 514.

In the pouch 510, the main body 512 and the cover 514 correspond to the main body 112 and the cover 114, respectively, which have previously been described with reference to FIGS. 1A through 1C. Accordingly, a detailed description of these elements will not be given herein.

The main body 512 includes a plurality of alignment protrusions 530. Each of the plurality of alignment protrusions 530 is provided at the lateral faces 512b of the main body 512 to have a hemispherical horizontal section 532 (hatching regions in FIG. 5A), unlike the alignment protrusion 130 provided at the corner of the lateral face 112b and having a fan-shaped horizontal section, as indicated by a hatching region labeled 132, as described above with reference to FIG. 1B.

Although FIG. 5A illustrates that the alignment protrusions 530 are provided all the corners of four lateral faces 512b, the invention is not limited to the illustrated example. Rather, two alignment protrusions 530 may be provided at a constant area of a first lateral face of the electrode assembly 520 from which the first electrode tabs 524 and the second electrode tabs 525 extend, and at another constant area of a second lateral face of the electrode assembly 520, the second lateral face being opposite to and facing the one lateral face of the electrode assembly 520.

The electrode assembly 520 includes a first electrode (not shown), a second electrode (not shown), a separator (not shown), a first electrode tab 524, a second electrode tab 525, a first electrode lead 526, a second electrode lead 527 and an insulating tape 528, and these elements correspond to the first electrode 121, the second electrode 122, the separator 123, the first electrode tab 124, the second electrode tab 125, the first electrode lead 126, the second electrode lead 127 and the insulating tape 128, respectively, which have previously been described with reference to FIGS. 1A through 1C. Accordingly, a detailed description of these elements will not be given herein.

The electrode assembly 520 includes at least one alignment hole 540 formed at its edge, the at least one alignment hole corresponding to the protrusions 530.

As shown in FIG. 5B, the at least one alignment hole 540 may be provided at all of four corners. Alternatively, the at least one alignment hole 540 may be formed at an edge of a first lateral face of the electrode assembly 520 from which the first electrode tabs 524 and the second electrode tabs 525 extend, and at an edge of a second lateral face of the electrode assembly 520, the second lateral face being opposite to and facing the one lateral face of the electrode assembly 520.

The protective circuit module 550 includes control devices 552 and external terminals 554. The protective circuit module 550 are substantially the same as the protective circuit module 150 including the control devices 152 and the external terminals 154, as described above with reference to FIG. 1C. Accordingly, a detailed description of these elements will not be given herein.

FIGS. 6A and 6B illustrate a pouch and an electrode assembly as component members of a secondary battery according to still another embodiment of the present invention. In the current embodiment, the pouch and the electrode assembly are shown in separate drawings, which is, however, for a better understanding of the invention, it is to be understood that the pouch and the electrode assembly are assembled with the secondary battery (100 of FIG. 1A) in actuality.

Referring to FIGS. 6A and 6B, the secondary battery according to still another embodiment of the present invention includes the pouch 610 and an electrode assembly 620.

In addition, the secondary battery includes a protective circuit module 650.

The pouch 610 includes a main body 612 and a cover 614.

In the pouch 610, the main body 612 and the cover 614 correspond to the main body 112 and the cover 114, respectively, which have previously been described with reference to FIGS. 1A through 1C. Accordingly, a detailed description of these elements will not be given herein.

The main body 612 includes a plurality of alignment protrusions 630. Each of the plurality of alignment protrusions 630 is provided at the lateral faces 612b of the main body 612 to have a horizontal section shaped of a rectangle 632 (hatching regions in FIG. 6A) in which the corner of the rectangle 632 is directed toward the interior of a cavity 616, unlike the alignment protrusion 130 having a horizontal section shaped of a fan 132, (hatching regions), as described above with reference to FIG. 1B.

The electrode assembly 620 includes a first electrode (not shown), a second electrode (not shown), a separator (not shown), a first electrode tab 624, a second electrode tab 625, a first electrode lead 626, a second electrode lead 627 and an insulating tape 628, and these elements correspond to the first electrode 121, the second electrode 122, the separator 123, the first electrode tab 124, the second electrode tab 125, the first electrode lead 126, the second electrode lead 127 and the insulating tape 128, respectively, which have previously been described with reference to FIGS. 1A through 1C. Accordingly, a detailed description of these elements will not be given herein.

The electrode assembly 620 includes at least one alignment hole 640 formed at its edge, the at least one alignment hole corresponding to the at least one protrusion 630.

In addition, the at least one alignment hole 640 are formed to have a shape conformal to that of the at least one protrusion 630.

The protective circuit module 650 includes control devices 652 and external terminals 654. The protective circuit module 650 are substantially the same as the protective circuit module 150 including the control devices 152 and the external terminals 154, as described above with reference to FIG. 1C. Accordingly, a detailed description of these elements will not be given herein.

FIGS. 7A and 7B illustrate a pouch and an electrode assembly as component members of a secondary battery according to another embodiment of the present invention. In the current embodiment, the pouch and the electrode assembly are shown in separate drawings, which is, however, for a better understanding of the invention, it is to be understood that the pouch and the electrode assembly are assembled with the secondary battery (100 of FIG. 1A) in actuality.

Referring to FIGS. 7A and 7B, the secondary battery according to still another embodiment of the present invention includes the pouch 710 and an electrode assembly 720.

In addition, the secondary battery includes a protective circuit module 750.

The pouch 710 includes a main body 712 and a cover 714.

In the pouch 710, the main body 712 and the cover 714 correspond to the main body 112 and the cover 114, respectively, which have previously been described with reference to FIGS. 1A through 1C. Accordingly, a detailed description of these elements will not be given herein.

The main body 712 includes a plurality of least one alignment protrusion 730. Unlike the alignment protrusion 130 provided at the corner of the lateral face 112b and having a fan-shaped horizontal section (hatching regions 132 in FIG. 1B), as shown in FIG. 7A, each of the plurality of alignment protrusions 730 has a horizontal section shaped of a triangle 532 (hatching regions in FIG. 7A) and an inclined surface directed toward a cavity 716.

The electrode assembly 720 includes a first electrode (not shown), a second electrode (not shown), a separator (not shown), a first electrode tab 724, a second electrode tab 725, a first electrode lead 726, a second electrode lead 727 and an insulating tape 728, and these elements correspond to the first electrode 121, the second electrode 122, the separator 123, the first electrode tab 124, the second electrode tab 125, the first electrode lead 126, the second electrode lead 127 and the insulating tape 128, respectively, which have previously been described with reference to FIGS. 1A through 1C. Accordingly, a detailed description of these elements will not be given herein.

The electrode assembly 720 includes at least one alignment hole 740 formed at its edge, the at least one alignment hole corresponding to the at least one protrusion 730.

In addition, the at least one alignment hole 740 are formed in a shape in which a chamfer part is formed at each corner of the electrode assembly 720 to correspond to the at least one protrusion 730.

The protective circuit module 750 includes control devices 752 and external terminals 754. The protective circuit module 750 are substantially the same as the protective circuit module 150 including the control devices 152 and the external terminals 154, as described above with reference to FIG. 1C. Accordingly, a detailed description of these elements will not be given herein.

FIG. 8 illustrates a secondary battery according to still another embodiment of the present invention.

Referring to FIGS. 8A and 8B, the secondary battery 800 according to still another embodiment of the present invention includes the pouch 810 and an electrode assembly 820.

In addition, the secondary battery 800 includes a protective circuit module 850.

The pouch 810 includes a main body 812 and a cover 814.

The main body 812 has a structure corresponding to that of the main body 112, which has previously been described with reference to FIGS. 1A through 1C. That is to say, the main body 812 is configured to have a bottom face 812a, lateral faces 812b and a sealing part, which correspond to the bottom face 112a, the lateral faces 112b and the sealing part 112c shown in FIGS. 1A through 1C.

The cover 814 is different from the cover 114 shown in FIGS. 1A through 1C. That is to say, as shown in FIG. 8, the cover 814 is provided to form symmetry relative to the main body 812, unlike the cover 114 shown in FIG. 1.

In such a manner, the secondary battery 800 according to the current embodiment of the present invention is provided with a cavity 816 based on the main body 812 and another cavity 816 based on the cover 814, thereby obtaining the double-capacity cavity 816, compared to the cavity 116 of the secondary battery 100 shown in FIGS. 1A through 1C.

Each of the main body 812 and the cover 814 include a plurality of alignment protrusions 830. The alignment protrusions 830 provided in the main body 812 are symmetrical to those 830 provided in the cover 814.

Since the alignment protrusions 830 are provided to correspond to the alignment protrusions 130 shown in FIGS. 1A through 1C, a detailed description thereof will not be given herein.

Various component members of the electrode assembly 820 correspond to those of the electrode assembly 120 shown in FIGS. 1A through 1C, except that a thickness of the electrode assembly 820 is increased to be adapted for the cavity 816. That is to say, the electrode assembly 820 includes a first electrode (not shown), a second electrode (not shown), a separator (not shown), a first electrode tab 824, a second electrode tab 825, a first electrode lead 826, a second electrode lead 827 and an insulating tape 828, and these elements correspond to the first electrode 121, the second electrode 122, the separator 123, the first electrode tab 124, the second electrode tab 125, the first electrode lead 126, the second electrode lead 127 and the insulating tape 128, respectively, which have previously been described with reference to FIGS. 1A through 1C. Accordingly, a detailed description of these elements will not be given herein.

The electrode assembly 820 includes at least one alignment hole 840, which correspond to the at least one alignment hole shown in FIGS. 1A through 1C, and a detailed description thereof will not be given herein.

The protective circuit module 850 includes control devices 852 and external terminals 854. The protective circuit module 850 are substantially the same as the protective circuit module 150 including the control devices 152 and the external terminals 154, as described above with reference to FIGS. 1A through 1C. Accordingly, a detailed description of these elements will not be given herein.

FIGS. 9A through 9C illustrate a method for manufacturing a secondary battery according to an embodiment of the present invention.

Referring to FIGS. 9A through 9C, the pouch 110 shown in FIG. 1B is first prepared.

Here, the pouch 210, 310, 410, 510, 610, 710 or 810 shown in FIG. 2A, 3A, 4A, 5A, 6A, 7A or 8A may also be used, instead of the pouch 110.

Next, the first electrode 121a, the second electrode 122a and the separator 123a shown in FIG. 1D are prepared.

Here, the first electrodes, the second electrodes and the separators of the electrode assemblies 220, 320, 420, 520, 620, 720 and 820 shown in FIG. 2A, 3A, 4A, 5A, 6A, 7A or 8A may also be used, instead of the first electrode 121a, the second electrode 122a and the separator 123a, respectively.

The first electrode 121a, the separator 123a and the second electrode 122a are sequentially stacked and accommodated in the cavity 116 of the pouch 110.

The pouch 110 includes a plurality of alignment protrusions 130 and each of the first electrode 121a, the separator 123a and the second electrode 122a include a plurality of alignment holes 140a. Accordingly, the first electrode 121a, the second electrode 122a and the separator 123a are easily aligned in the cavity 116 of the pouch 110.

When the stacking of the first electrode 121a, the separator 123a and the second electrode 122a is completed in the cavity 116, the first electrode tabs 124 extending from one lateral face of the first electrode 121a and the second electrode tabs 125 extending from one lateral face of the second electrode 122a are connected to the first electrode lead 126 and the second electrode lead 127, respectively. Here, the connecting of the first electrode lead 126 and the second electrode lead 127 is performed by welding, for example, resistance welding.

To protect the first electrode lead 126 and the second electrode lead 127, the insulating tape 128 is formed at a predetermined region of each of the first electrode lead 126 and the second electrode lead 127.

Next, the main body 112 is shielded by the cover 114, followed by fusing the sealing part 112c of the main body 112 with the sealing part 114b of the cover 114, thereby hermetically sealing the cavity 116 of the main body 112.

The protective circuit module 150 is connected to the first electrode lead 126 and the second electrode lead 127, thereby completing the secondary battery according to the illustrated embodiment of the present invention.

FIGS. 10A through 10C illustrate a method for manufacturing a secondary battery according to still another embodiment of the present invention.

Referring to FIGS. 10A through 10C, the pouch 110 shown in FIG. 1B is first prepared.

Here, the pouch 210, 310, 410, 510, 610, 710 or 810 shown in FIG. 2A, 3A, 4A, 5A, 6A, 7A or 8 may also be used, instead of the pouch 110.

Next, the first electrode 121b and the second electrode 122b and the separator 123a shown in FIG. 1E are prepared.

Here, the first electrodes and the second electrodes of the electrode assemblies 220, 320, 420, 520, 620, 720 and 820 shown in FIG. 2B, 3B, 4B, 5B, 6B, 7B or 8 may also be used, instead of the first electrode 121b and the second electrode 122b, respectively. Specifically, the first electrode 121b or the second electrode 122b of the electrode assembly 820 includes the insulating-layer separator 123b.

Although FIG. 10A illustrates that both of the first electrode 121b and the second electrode 122b include the insulating-layer separator 123b, the insulating-layer separator 123b may be provided on only one of the first electrode 121b and the second electrode 122b.

Meanwhile, the insulating-layer separator 123b may be provided on the first electrode 121b or the second electrode 122b through a liquid coating method. In detail, the insulating-layer separator 123b is supplied in a slurry or liquid phase. Then, the slurry or liquid phase insulating-layer separator 123b is coated on a surface of the first electrode 121b or the second electrode 122b using the liquid coating method, for example, dipping or spraying.

Subsequently, the first electrode 121b and the second electrode 122b including the insulating-layer separator 123b are sequentially stacked and accommodated in the cavity of the pouch 110.

Here, the pouch 110 includes the plurality of alignment protrusions 130 and each of the first electrode 121b and the second electrode 122b include the plurality of alignment holes 140b. Accordingly, the first electrode 121b and the second electrode 122b are easily aligned in the cavity 116.

When the stacking of the first electrode 121b and the second electrode 122b is completed in the cavity 116, the first electrode tabs 124 extending from one lateral face of the first electrode 121b and the second electrode tabs 125 extending from one lateral face of the second electrode 122b are connected to the first electrode lead 126 and the second electrode lead 127, respectively. Here, the connecting of the first electrode lead 126 and the second electrode lead 127 is performed by welding, for example, resistance welding.

Here, the forming of the insulating tape (128 of FIG. 9C) in the first electrode lead 126 and the second electrode lead 127 may be omitted.

This is because the insulating-layer separator 123b is capable of protecting the first electrode tabs 124 and the second electrode tabs 125 by providing the insulating-layer separator 123b in a predetermined region of each of the first electrode tabs 124 and the second electrode tabs 125.

FIGS. 11A through 11C illustrate a method for manufacturing a secondary battery according to still another embodiment of the present invention.

Referring to FIGS. 11A through 11C, the pouch 110 shown in FIG. 1B is first prepared.

Here, the pouch 210, 310, 410, 510, 610, 710 or 810 shown in FIG. 2A, 3A, 4A, 5A, 6A, 7A or 8 may also be used, instead of the pouch 110.

Next, the first electrode 121c and the second electrode 122c and the separator 123a shown in FIG. 1F are prepared.

Although FIG. 11A illustrates that the first electrode 121c is encapsulated by the two sheets of separators 123c, the invention is not limited thereto. Rather, the second electrode 122b may also be encapsulated by the two sheets of separators 123c.

Meanwhile, the first electrode 121c is encapsulated by the two sheets of separators 123c by fusing edges of the two sheets of separators 123c by ultrasonic fusion or thermal fusion.

Next, the first electrode 121c or the second electrode 122c encapsulated by the two sheets of separators 123c are sequentially stacked and accommodated in the cavity 116 of the pouch 110.

Here, since the pouch 110 includes the plurality of alignment protrusions 130 and each of the first electrode 121c and the second electrode 122c include the plurality of alignment holes 140c, the first electrode 121c and the second electrode 122c are easily aligned in the cavity 116 of the pouch 110.

When the stacking of the first electrode 121c and the second electrode 122c is completed in the cavity 116, the first electrode tabs 124 extending from one lateral face of the first electrode 121c and the second electrode tabs 125 extending from one lateral face of the second electrode 122c are connected to the first electrode lead 126 and the second electrode lead 127, respectively. Here, the connecting of the first electrode lead 126 and the second electrode lead 127 is performed by welding, for example, resistance welding.

FIGS. 12A through 12C illustrate a method for manufacturing a secondary battery according to still another embodiment of the present invention.

Referring to FIGS. 12A through 12C, the pouch 810 shown in FIG. 8 is first prepared.

Next, the first electrode 821, the second electrode 822 and the separator 823 are prepared.

Here, the first electrode 121a, the second electrode 122b and the separator 123a shown in FIG. 1D may be used instead of the first electrode 821, the second electrode 822 and the separator 823, respectively. Alternatively, the first electrode 121b and the second electrode 121b including the separator 123b, as shown in FIG. 1E, may be used instead of the first electrode 821, the second electrode 822 and the separator 823, respectively. Alternatively, the first electrode 121b and the second electrode 121b encapsulated by the two sheets of separators 123c, as shown in FIG. 1F, may be used instead of the first electrode 821, the second electrode 822 and the separator 823, respectively.

The first electrodes and the second electrodes of the electrode assemblies 220, 320, 420, 520, 620 or 720 shown in FIG. 2B, 3B, 4B, 5B, 6B or 7B may also be used, instead of the first electrode 821 and the second electrode 822, respectively.

Subsequently, the first electrode 821, the separator 823 and the second electrode 822 are sequentially stacked to then be accommodated in each cavity 816 of the main body 816 and the cover 814 of the pouch 810.

Here, the electrodes finally stacked in the cavities 816 of the main body 812 and the cover 814 preferably have different polarities from each other. This is for making the electrodes finally stacked in the cavities 816 of the main body 812 and the cover 814 become different electrodes when the cavity 816 of the main body 816 is combined with the cavity 816 of the cover 814.

Here, since the pouch 110 includes the plurality of alignment protrusions 830 and each of the first electrode 821 and the second electrode 822 include the plurality of alignment holes 840, the first electrode 821 and the second electrode 822 are easily aligned in the cavities 816 of the pouch 810.

When the stacking of the first electrode 821, the second electrode 822 and the separator 823 is completed in the cavities 816, and the cover 814 is combed with the main body 812, the cavity 816 of the main body 812 and the cavity 816 of the cover 814 are disposed to correspond to each other.

Next, the first electrode tabs 824 extending from one lateral face of the first electrode 821 and the second electrode tabs 825 extending from one lateral face of the second electrode 822 are connected to the first electrode lead 826 and the second electrode lead 827, respectively. Here, the connecting of the first electrode lead 826 and the second electrode lead 827 is performed by welding, for example, resistance welding.

To protect the first electrode lead 826 and the second electrode lead 827, an insulating tape 828 is formed at a predetermined region of each of the first electrode lead 826 and the second electrode lead 827.

Next, a sealing part 812c of the main body 812 is sealed with a sealing part 814c of the cover 814, thereby hermetically sealing the cavities 816 of the main body 812 and the cover 814.

The protective circuit module 850 is connected to the first electrode lead 826 and the second electrode lead 827, thereby completing the secondary battery according to the illustrated embodiment of the present invention.

While the present invention has been described in connection with certain exemplary embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, and equivalents thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A through 1F illustrate a secondary battery according to an embodiment of the present invention;

FIGS. 2A and 2B illustrate a pouch and an electrode assembly as component members of a secondary battery according to another embodiment of the present invention;

FIGS. 3A and 3B illustrate a pouch and an electrode assembly as component members of a secondary battery according to still another embodiment of the present invention;

FIG. 4 illustrates a secondary battery according to still another embodiment of the present invention;

FIGS. 5A and 5B illustrate a pouch and an electrode assembly as component members of a secondary battery according to still another embodiment of the present invention;

FIGS. 6A and 6B illustrate a pouch and an electrode assembly as component members of a secondary battery according to still another embodiment of the present invention;

FIGS. 7A and 7B illustrate a pouch and an electrode assembly as component members of a secondary battery according to another embodiment of the present invention;

FIG. 8 illustrates a secondary battery according to still another embodiment of the present invention;

FIGS. 9A through 9C illustrate a method for manufacturing a secondary battery according to an embodiment of the present invention;

FIGS. 10A through 10C illustrate a method for manufacturing a secondary battery according to still another embodiment of the present invention;

FIGS. 11A through 11C illustrate a method for manufacturing a secondary battery according to still another embodiment of the present invention; and

FIGS. 12A through 12C illustrate a method for manufacturing a secondary battery according to still another embodiment of the present invention.

DESCRIPTION OF THE SYMBOLS IN MAIN PORTIONS OF THE DRAWINGS

110: Pouch
112: Main Body

114: Cover
120: Electrode Assembly

130: Alignment Protrusion
140: Alignment Hole

SECONDARY BATTERY AND METHOD FOR MANUFACTURING THE SAME

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CPC

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