Case for secondary battery and lithium secondary battery using the same

This application claims the benefit of Korean Patent Application No. 10-2009-0115148, filed on Nov. 26, 2009, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein, by reference.

1. Field

Aspects of the present disclosure relate to a case for secondary battery and a lithium secondary battery using the same.

2. Description of the Related Art

A secondary battery can be repeatedly charged and discharged. A secondary battery is a kind of chemical battery that stores electric energy between electrodes, through a chemical reaction. Currently, secondary batteries include lead batteries, nickel-cadmium batteries, nickel-hydrogen batteries, lithium ion batteries, lithium ion polymer batteries, and the like. Secondary batteries are divided into a cylinder-type, prismatic-type, and the like, in accordance with their appearances.

Lithium ion batteries have a high energy density per unit volume. Therefore, various studies on lithium ion batteries have been conducted, to apply them to digital conversions, hybrid automobiles, robot industries, and the like.

In one exemplary embodiment, there is provided a case for a secondary battery, in which a bottom wall of the case is pushed to the outside of the case under a longitudinal compression environment, so that it is possible to improve stability under longitudinal compression.

In another exemplary embodiment, there is provided a lithium secondary battery, in which a case having an improved stability for longitudinal compression is used, so that it is possible to inhibit an electrode assembly from being pierced by a bottom wall of the case, under a longitudinal compression environment.

According to an aspect of the present disclosure, there is provided a case for secondary battery, which includes first and second main walls opposite to each other; first and second side walls connected to the two main walls; and a bottom wall connected to ends of the main walls and the side walls. The bottom wall has a first notch extending between the main walls. The thickness of the bottom wall may decrease from the side walls to a central portion thereof. The thickness of the bottom wall may be decreased gradually.

According to another aspect of the present disclosure, there is provided a lithium secondary battery including the aforementioned case, and an electrode assembly disposed in the case, an electrolyte, and a cap assembly for sealing the case. The electrode assembly includes positive and negative electrode layers isolated from each by a separator.

In one exemplary embodiment, the first notch is formed on the outer surface of the bottom wall.

In one exemplary embodiment, the bottom wall includes a plurality of the first notches, evenly spaced apart between the first and second side walls.

In one exemplary embodiment, the bottom wall includes a plurality of the first notches disposed in pairs, between the side walls.

In one exemplary embodiment, the bottom wall includes three of the first notches.

According to some aspects, the bottom wall may further include second notches positioned at boundaries between the bottom wall and the main walls. The second notches may be respectively connected to ends of the first notches.

In one exemplary embodiment, the depth of the first and second notches is about 30 to 50% of the thickness of the bottom wall.

In one exemplary embodiment, the case may have rounded external corners at the interfaces of the main walls and the side walls.

According to some aspects, the case is formed of aluminum or an aluminum alloy.

According to exemplary embodiments of the present disclosure, there is provided secondary batteries including the above recited cases.

Additional aspects and/or advantages of the present disclosure will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the present disclosure.

These and/or other aspects and advantages of the present disclosure will become apparent and more readily appreciated from the following description of the exemplary embodiments, taken in conjunction with the accompanying drawings, of which:

FIG. 1 is a perspective view of a case for secondary battery according to an embodiment of the present disclosure.

FIG. 2A is a longitudinal sectional view of the case for secondary battery, taken along line I-I in FIG. 1 .

FIG. 2B is a longitudinal sectional view of the case for secondary battery, taken along line I-I in FIG. 1 .

FIG. 3 is a perspective view of a case for secondary battery according to another embodiment of the present disclosure.

FIG. 4 is a longitudinal sectional view of the case for secondary battery in FIG. 3 .

FIG. 5 is a perspective view of a case for secondary battery according to still another embodiment of the present disclosure.

FIG. 6 is a longitudinal sectional view of the case for secondary battery in FIG. 5 .

FIG. 7 is a perspective view of a case for secondary battery according to still another embodiment of the present disclosure.

FIG. 8 is a longitudinal sectional view of the case for secondary battery in FIG. 7 .

FIGS. 9A to 9D are partial perspective views illustrating notch structures applicable to the case for secondary battery according to embodiments of the present disclosure.

FIG. 10 is an exploded perspective view of a lithium secondary battery using the case of FIG. 4 .

FIGS. 11A and 11B are schematic sectional view illustrating longitudinal compression characteristics of the lithium secondary battery of FIG. 10 .

In the following detailed description, only certain exemplary embodiments of the present disclosure have been shown and described, simply by way of illustration. As those skilled in the art would realize, the described embodiments may be modified in various different ways, all without departing from the spirit or scope of the present disclosure. Accordingly, the drawings and description are to be regarded as illustrative in nature and not restrictive. In addition, when an element is referred to as being “on” another element, it can be disposed directly on another element or may be indirectly disposed on the other element, with one or more intervening elements interposed therebetween. Also, when an element is referred to as being “connected to” another element, it can be directly connected to another element or be indirectly connected to another element, with one or more intervening elements interposed therebetween. Hereinafter, like reference numerals refer to like elements. In the drawings, the thickness or size of layers are exaggerated for clarity and not necessarily drawn to scale.

FIG. 1 is a perspective view of a case 10 for a secondary battery, according to an exemplary embodiment of the present disclosure. FIG. 2A is a longitudinal sectional view of the case 10 , taken along line I-I in FIG. 1 . FIG. 2B is a longitudinal sectional view of the case 10 , taken along line I-I in FIG. 1 .

Referring to FIGS. 1 , 2 A and 2 B, the case 10 includes a first main wall 12 a , a second main wall 12 b , a first side wall 12 c , a second side wall 12 d , a bottom wall 14 , and an opening opposite to the bottom wall 14 . The first and second main walls 12 a and 12 b are formed opposite to each other, at a predetermined interval. The first and second main walls 12 a and 12 b have substantially the same size and shape. The first and second side walls 12 c and 12 d are formed opposite to each other, at a predetermined interval. The first and second side walls 12 c and 12 d have substantially the same size and shape. The main walls 12 a and 12 b have a larger surface area than the side walls 12 c and 12 d.

Sides of the first and second main walls 12 a and 12 b are respectively connected to the first side wall 12 c , and opposing sides of the first and second main walls 12 a and 12 b are respectively connected to the second side wall 12 d . As such, the case 10 may at least partially define a substantially rectangular box. In one exemplary embodiment, corners formed between the main and side walls may have a rounded or curved. In this case, a cross-section the case 10 taken in the x-y plane may be elliptical, such that the case 10 is tubular.

The bottom wall 14 is connected to ends of the main walls 12 a and 12 b and the side walls 12 c and 12 d . In one exemplary embodiment, the bottom wall 14 may be integrally formed with the first and second main walls 12 a and 12 b and/or the first and second side walls 12 c and 12 d , using a single piece of material. The case 10 has an opening 16 defined by the main walls 12 a and 12 b , and the side walls 12 c and 12 d . The opening 16 opposes the bottom wall 14 , with the internal space of the case 10 interposed therebetween.

The thickness of the walls of the case 10 may be in the range of about 0.2 to 1.0 mm. Aluminum or an aluminum alloy may be used as the material of the case 10 .

The case 10 has a structure that allows the bottom wall 14 to be opened to the outside of the case 10 , under a longitudinal compression environment. The opening of the bottom wall 14 is facilitated by the structure of the bottom wall 14 . In particular, the bottom wall 14 may vary in thickness and may include a notch structure.

The bottom wall 14 has a first thickness H 1 , at edge portions thereof that are disposed adjacent to the two side walls 12 c and 12 d . The bottom wall 14 has a second thickness H 2 at a central portion thereof, disposed between the edge portions. The thickness H 1 is greater than the thickness H 2 . The thickness of the bottom wall may be gradually increased, from the central portion to edge portions.

The difference between the first thickness H 1 and the second thickness H 2 ranges from about 0.001 mm to 0.5 mm. For example, when the first thickness H 1 is 1.0 mm, the second thickness H 2 may be 0.5 mm. The difference between the first thickness H 1 and the second thickness H 2 may be smaller than about 0.001 mm. That is, the difference between the first thickness H 1 and the second thickness H 2 may be minute.

With regard to the notch structure, the bottom wall 14 may include a main notch 18 (also referred to herein as a first notch) positioned on the inner surface of the bottom wall 14 , at the central portion. The main notch 18 extends across the inner surface of the bottom wall 14 , between the first and second main walls 12 a and 12 b . The main notch 18 may be formed on a portion of a line extending across the inner surface of the bottom wall 14 , from the first main wall 12 a to the second main wall 12 b . The main notch 18 may have a V-shaped cross-section. However, the main notch 18 may have various structures and shapes, as long as the thickness (strength) of the bottom wall 14 can be appropriately decreased.

A combination of the shape of the bottom wall 14 and the main notch 18 allow the case 10 is opened to the outside, under a longitudinal compression environment. A longitudinal compression environment refers to an environment similar to a longitudinal compression test, in which the lithium secondary battery 10 is compressed with a force of 13 KN, in both the x-direction and the y-direction (hereinafter, also referred to as both longitudinal directions) for two seconds. In other words, the longitudinal compression environment refers to pressure applied to both side walls of a battery.

As illustrated in FIG. 2B , according to another exemplary embodiment, the case 10 may include a pair of auxiliary notches 19 a and 19 b positioned on the bottom wall 14 , at the boundaries between the bottom wall 14 and the first and second main walls 12 a and 12 b . The two auxiliary notches 19 a and 19 b are also referred to as second notches. The second notch, positioned between the first main wall 12 a and a boundary surface of the bottom wall 14 , may be referred to as a 2A-th notch, and the second notch positioned between the second main wall 12 b and a boundary surface of the bottom wall 14 , may be referred to as a 2B-th notch.

When the case 10 includes the auxiliary notches 19 a and 19 b and the main notch 18 , the bottom wall 14 is bent outward, under a longitudinal compression environment. The structure and shape of the auxiliary notches 19 a and 19 b may be substantially the same as the main notch 18 .

FIG. 3 is a perspective view of a case 10 a for secondary battery, according to another exemplary embodiment of the present disclosure. FIG. 4 is a longitudinal sectional view of the case 10 a . Referring to FIGS. 3 and 4 , the case 10 a has a bottom wall 14 a that includes a notch structure, so that a bottom wall 14 a is opened to the outside of the case 10 a , under a longitudinal compression environment.

The first thickness H 1 of edge portions of the bottom wall 14 a , adjacent to two side walls 12 c and 12 d , is thicker than the second thickness H 2 of a central portion of the bottom wall 14 a , positioned between the edge portions. That is, the thickness of the bottom wall 14 a may be gradually increased, from the central portion to the side walls 12 c and 12 d.

The bottom wall 14 a includes a main notch 18 a . The main notch 18 a is formed at the central portion, in the outer surface of the bottom wall 14 a and extends between the first and second main walls 12 a and 12 b . The bottom wall 14 a may have auxiliary notches like those illustrated in FIG. 2B . The case 10 a may be substantially identical to the case 10 , except that the main notch 18 a is formed in the outer surface of the bottom wall 14 a.

FIG. 5 is a perspective view of a case 10 b for a secondary battery, according to still another exemplary embodiment of the present disclosure. For convenience of illustration, a notch structure formed on an inner surface of a bottom wall 14 b is shown as a dotted line on the outside of the bottom wall 14 b , in FIG. 5 . FIG. 6 is a longitudinal sectional view of the case 10 b . Referring to FIGS. 5 and 6 , the bottom wall 14 b is designed to be opened to the outside of the case 10 b under, a longitudinal compression environment.

In the bottom wall 14 b , the first thickness H 1 of edge portions of the bottom wall 14 b , adjacent to two side walls 12 c and 12 d , is thicker than the second thickness H 2 of the central portion of the bottom wall 14 b , positioned between the edge portions of the bottom wall 14 b . Particularly, the bottom wall 14 b has inclined portions 15 formed adjacent to the side walls 12 c and 12 d . The inclined portions 15 increase the thickness of the boundary between the side walls 12 c and 12 d and the bottom wall 14 b . Thus, the inclined portions 15 facilitate outward deformation of the bottom wall 14 d , under a longitudinal compression environment, until the bottom wall 14 d is ruptured by the compression.

The bottom wall 14 b may have a consistent thickness, between the two inclined portions 15 . The bottom wall 14 b includes first, second, and third main notches. The thickness of the bottom wall 14 b , between the inclined portions 15 , may remain constant, except for in areas including the main notches 20 a , 20 b , and 20 c . The second main notch 20 b is positioned on the central portion of the bottom wall 14 b between the side walls 12 c and 12 d . The first main notch 20 a is positioned on the bottom wall 14 b , between the side wall 12 d and the second main notch 20 b . The third main notch 20 c is positioned on the bottom wall 14 b , between the side wall 12 c and the second main notch 20 b . The main notches 20 a , 20 b , and 20 c are formed in the inner surface of the bottom wall 14 b and extend between first and second main walls 12 a and 12 b . According to some aspects the main notches 20 a , 20 b , and 20 c may extend to contact the main walls 12 a and 12 b , i.e., may be shorter than the width of the bottom wall 14 b , or may extend all the way to the main walls 12 a and 12 b.

The notch structure may have at least one of the auxiliary notches illustrated in FIG. 2B . The case 10 b is substantially identical to the case 10 , except the bottom wall 14 b is generally flat, except for the inclined portions 15 and the main notches 20 a , 20 b , and 20 c , on the inner surface of the bottom wall 14 b . The three main notches 20 a , 20 b and 20 c may be referred to as 1A-th, 1B-th, and 1C-th notches, respectively.

FIG. 7 is a perspective view of a case 10 c for secondary battery, according to still another exemplary embodiment of the present disclosure. For convenience of illustration, a notch structure formed at an inner surface of a bottom wall 14 c is shown as a dotted line projected on an outer surface of the bottom wall 14 c , in FIG. 7 . FIG. 8 is a longitudinal sectional view of the case 10 c.

Referring to FIGS. 7 and 8 , the case 10 c has a bottom wall structure and a notch structure, so that a bottom wall 14 c is opened to the outside of the case 10 c , under a longitudinal compression environment. In particular, the bottom wall 14 c is thicker adjacent to side walls 12 c and 12 d than in a central portion thereof.

The bottom wall 14 c includes inclined portions 15 c adjacent to the side walls 12 c and 12 d . The inclined portions 15 c increase the thickness of the boundaries between the side walls 12 c and 12 d and the bottom wall 14 c . Thus, the inclined portions 15 c facilitate an outward expansion of the bottom wall 14 c , under a longitudinal compression environment. The thickness of the bottom wall 14 c , between the two inclined portions 15 c , may be decreased from the outside portions of the bottom wall 14 c to the inside portion of the bottom wall 14 c.

The bottom wall 14 c includes a notch structure. In particular, the bottom wall 14 c includes a pair of fourth main notches 21 a and 21 b and a pair of fifth main notches 21 c and 21 d on the inner surface thereof. The fourth main notches 21 a and 21 b are positioned on the bottom wall 14 c adjacent to the second side wall 12 d , between the first and second side walls 12 c and 12 d . The fifth main notches 21 c and 21 d are positioned adjacent to the first side wall 12 c , the first and second side walls 12 c and 12 d . The pairs of main notches 21 a , 21 b , 21 c , and 21 d extend between first and second main walls 12 a and 12 b.

The bottom wall 14 c may further include at least one of the auxiliary notches illustrated in FIG. 2B . Although the four main notches 21 a , 21 b , 21 c , and 21 d are described, other numbers of notches may be employed. In addition, the same operational effect can be substantially obtained, if fewer main notches are combined with auxiliary notches. That is, the fourth or fifth main notches may each include at least one notch. The fourth and fifth main notches may be referred to as 1D-th and 1E-th notches, respectively.

FIGS. 9A to 9D are partial perspective views illustrating notches having modified structures, which are applicable to the any of the previously described notches. Referring to FIG. 9A , a notch 18 formed in a bottom wall 14 of a case may have a V-shaped, widthwise, cross-section.

When the thickness t of the bottom wall 14 is about 0.2 to 1.0 mm, the depth d of the notch 18 may be formed to have about 30 to 50% of the thickness t of the bottom wall 14 . If the depth d of the notch 18 is too deep, the case may have reduced durability. If the depth d of the notch 18 is too shallow, the bottom wall 14 may not open under a desired pressure.

Referring to FIG. 9B , a bottom wall 14 d of a case, according to another exemplary embodiment may have a notch 18 d that is V-shaped. In other aspects the notch 18 d may be zigzag shaped such that it includes one or more bent portions 18 g.

Referring to FIG. 9C , a bottom wall 14 e of a case, according to still another exemplary embodiment, may have a notch 18 e that has a semi-circular, widthwise, cross-section. Here, The notch 18 e basically corresponds to a main notch.

Referring to FIG. 9D , a bottom wall 14 f of a case, according to still another exemplary embodiment may have an auxiliary notch 19 c with a semi-circular, widthwise, cross-section. The notch 19 c is formed on the bottom wall 14 f , at the boundary between the first main wall 12 a and the bottom wall 14 f.

FIG. 10 is an exploded perspective view of a lithium secondary battery 100 , including the case of FIG. 4 . Referring to FIG. 10 , the lithium secondary battery 100 a case 11 , an electrode assembly 112 accommodated in the case 11 , and a cap assembly 120 sealing a top opening 16 of the case 11 . Here, the case 11 has a bottom wall 14 b including a notch structure 108 , which are designed so that a bottom wall 14 b is opened externally, under a longitudinal compression environment, i.e., an increase in the internal pressure of the lithium secondary battery 100 .

The case 11 includes two opposing main walls 12 ; two opposing side walls 13 connecting the main walls 12 ; the bottom wall 14 b , which is connected to ends of the main walls 12 and the side wall 13 ; and an opening 16 opposite to the bottom wall 14 b.

The case 11 is substantially identical to the case 10 b illustrated in FIG. 5 . However, any of the cases described herein and/or the modifications thereto may be applied to the battery 100 .

The electrode assembly 112 includes a first electrode plate 113 , the second electrode plate 115 , and a separator 114 . The first and second electrode plates 113 and 115 may be positive and negative electrode plates respectively, or vice versa. The first and second electrode plates 113 and 115 may be stacked with the separator 114 interposed therebetween and then wound in a jellyroll form. A first electrode tab 116 is welded to the first electrode plate 113 , and a second electrode tab 117 is welded to the second electrode plate 115 . End portions of the first and second electrode tabs 116 and 117 protrude toward the cap assembly 120 .

The cap assembly 120 includes a cap plate 140 , an insulating plate 150 , a terminal plate 160 , and an electrode terminal 130 . The cap assembly 120 is connected to the top opening 16 of the case 11 with a separate insulating body 170 interposed therebetween, so as to seal the case 11 .

The cap plate 140 is formed as a metal plate having a size and shape corresponding to the top opening 16 of the case 11 . Light-weight aluminum or a light-weight aluminum alloy may be used as the material of the cap plate 140 . A first terminal through-hole 141 is formed in the center of the cap plate 140 . An electrolyte injection hole 142 is formed at one side of the cap plate 140 .

The first terminal through-hole 141 is formed in the cap plate 140 and has a larger diameter than that of the electrode terminal 130 . The electrode terminal 130 is inserted into the first terminal through-hole 141 , with a tubular gasket 146 interposed therebetween. The gasket 146 insulates the electrode terminal 130 from the cap plate 140 .

After the cap assembly 120 is connected to the opening 16 of the case 11 , an electrolyte is injected into the case 11 , through the electrolyte injection hole 142 . The electrolyte injection hole 142 is sealed by a separate sealing member. The electrolyte may be a solid polymer containing lithium salt or a liquid polymer in which the lithium salt is dissociated in an organic solvent.

The insulating plate 150 insulates the cap plate 140 from the terminal plate 160 . An insertion groove 152 is provided in a lower surface of the insulating plate 150 . The insertion groove 152 has a size corresponding to that of the terminal plate 160 , so that the terminal plate 160 can be inserted therein. The insulating plate 150 is provided with a second terminal through-hole 151 , formed at a position corresponding to the first terminal through-hole 141 . The second terminal through-hole 151 is formed to have a diameter almost identical to that of the electrode terminal 130 .

The terminal plate 160 may be formed with nickel or nickel alloy. The terminal plate 160 is provided with a third terminal through-hole 161 formed at a position corresponding to the second terminal through-hole 151 of the insulating plate 150 . The electrode terminal 130 passes through the second terminal through-hole 151 , is inserted into the third terminal through-hole 161 , and is connected to the insulating body 170 .

The insulating body 170 is provided with a first electrode tab hole 171 and a second electrode tab hole 172 . The first electrode tab 116 is connected to the cap plate 140 , by passing through the first electrode tab hole 171 . The second electrode tab 117 is connected to the electrode terminal 130 , by passing through the second electrode tab hole 172 . The insulating body 170 is connected to the lower portion of the cap assembly 120 , and thus, allows the cap assembly 120 to be electrically isolated from the electrode assembly 112 .

In the lithium secondary battery 100 , the bottom wall 14 b can be opened to the outside, due to the structure of the bottom wall 14 b , under a longitudinal compression environment. Thus, the lithium secondary battery 100 can prevent, in some circumstances, the electrode assembly 12 from being pierced by the bottom wall 14 b , under a longitudinal compression environment. Accordingly, it is possible to prevent the lithium secondary battery from exploding.

FIGS. 11A and 11B are schematic sectional view illustrating longitudinal compression characteristics of the lithium secondary battery 110 of FIG. 10 , before and after a force F of 13 KN is applied in both width directions, for two seconds. After the force is applied, the bottom wall 14 b of the case 10 b is opened to the outside thereof. Thus, it is possible to prevent the electrode assembly 112 from being pierced by the bottom wall 14 b.

In a comparative lithium secondary using a case having a conventional bottom wall, when the case is collapsed during a longitudinal compression test, the bottom wall is folded to the inside and outside of the case. In this case, portions of the folded bottom wall pierce the electrode assembly of the battery. Therefore, in the comparative example, the longitudinal compression test results in an explosion.

However, in a lithium secondary according to the present disclosure, when a compressive load is applied, a bottom wall of a case is opened to the outside thereof, so that it is possible to prevent an electrode assembly from being pierced by the bottom wall. Accordingly, it is possible to prevent the lithium secondary battery from easily proceeding to an explosion mode.

Although a few exemplary embodiments of the present disclosure have been shown and described, it would be appreciated by those skilled in the art that changes may be made in these exemplary embodiments, without departing from the principles and spirit of the disclosure, the scope of which is defined in the claims and their equivalents.