LEAD TAB FOR SECONDARY BATTERY, MANUFACTURING APPARATUS THEREOF, AND SECONDARY BATTERY COMPRISING SAME

Abstract

A lead tab for a secondary battery, according to an embodiment of the present invention, includes a metal lead having a long rectangular plate shape in a first direction, a first insulation film formed on a lower surface of the metal lead in a second direction crossing the first direction, and a second insulation film formed on an upper surface of the metal lead in the second direction so as to correspond to the first insulation film, wherein each of the first insulation film and the second insulation film has a magnetic member which is induction-heated by an alternating magnetic field.

Claims

1-14. (canceled)

15. A lead tab for a secondary battery comprising: a metal lead having an elongated rectangular plate shape such that a long side of the elongated rectangular plate shape extends in a first direction; a first insulation film formed at a lower side of the metal lead in a second direction perpendicular to the first direction; and a second insulation film formed at an upper side of the metal lead in the second direction, wherein each of the first insulation film and the second insulation film comprises a magnetic member induction-heated by an alternating magnetic field.

16. The lead tab for the secondary battery according to claim 15, wherein a region of the first insulation film including a center of the first insulation film is bonded to the lower side of the metal lead, and a region of the second insulation film including a center of the second insulation film is bonded to the upper side of the metal lead, wherein a remaining region of the first insulation film and a remaining region of the second insulation film are bonded to each other.

17. The lead tab for the secondary battery according to claim 16, wherein the metal lead, the first insulation film, and the second insulation film are bonded to each other by thermal fusion.

18. The lead tab for the secondary battery according to claim 16, wherein the magnetic member comprises a first magnetic member formed both on a bonding surface of the first insulation film bonded to the metal lead and on a bonding surface of the first insulation film bonded to the second insulation film and a second magnetic member formed both on a bonding surface of the second insulation film bonded to the metal lead and on a bonding surface of second insulation film bonded to the first insulation film.

19. The lead tab for the secondary battery according to claim 15, wherein the magnetic member is added to the first insulation film and the second insulation film in a powder form.

20. The lead tab for the secondary battery according to claim 15, wherein the magnetic member comprises a metal-based, a ceramic-based, or a oxide-based magnetic material.

21. An apparatus for manufacturing a lead tab for a secondary battery comprising: a first induction heating head and a second induction heating head for pressing and bonding a first insulation film, a metal lead, and a second insulation film, wherein each of the first induction heating head and the second induction heating head comprises an induction coil that emits an alternating current (AC) magnetic field by supplying AC power.

22. The apparatus for manufacturing a lead tab for the secondary battery according to claim 21, wherein the first induction heating head and the second induction heating head drive to pressurize the first insulation film, the metal lead, and the second insulation film positioned between the first induction heating head and the second induction heating head, wherein the first and second induction coils emit an alternating magnetic field according to a supply of the AC power for bonding of a partial region of the first insulation film and the metal lead, bonding of a partial region of the second insulation film and the metal lead, and bonding of a remaining region of the first insulation film and a remaining region of the second insulation film.

23. The apparatus for manufacturing a lead tab for the secondary battery according to claim 21, wherein the first and second induction coils are implemented as a winding induction coil or a copper tube induction coil.

24. The apparatus for manufacturing a lead tab for the secondary battery according to claim 21, wherein the first induction heating head comprises: a first induction heating body for accommodating the first induction coil; and a first elastic pad provided on a side of the first induction heating body facing the second induction heating head, wherein the second induction heating head comprises: a second induction heating body for accommodating the second induction coil; and a second elastic pad provided on a side of the second induction heating body facing the first induction heating head.

25. The apparatus for manufacturing a lead tab for the secondary battery according to claim 24, wherein each of the first elastic pad and the second elastic pad comprises a releasing agent formed on a side in contact with the metal lead, the first insulation film, or the second insulation film.

26. The apparatus for manufacturing a lead tab for the secondary battery according to claim 24, wherein a heat resistance temperature of each of the first elastic pad and the second elastic pad is higher than a melting temperature of film members of the first insulation film and the second insulation film.

27. The apparatus for manufacturing a lead tab for the secondary battery according to claim 21, further comprising a first heating head and a second heating head temporarily bonding the first insulation film, the metal lead, and the second insulation film, wherein the first induction heating head and the second induction heating head pressurize and bond the first insulation film, the metal lead, and the second insulation film.

28. A battery unit comprising: a lead tab for the battery unit comprising: a metal lead having an elongated rectangular plate shape such that a long side of the elongated rectangular plate shape is in a first direction, a first insulation film formed at a lower side of the metal lead in a second direction perpendicular to the first direction, and a second insulation film formed at an upper side of the metal lead in the second direction, wherein each of the first insulation film and the second insulation film comprise a magnetic member induction-heated by an alternating magnetic field; a battery; a terminal drawn out from an electrode plate of the battery and connected to the lead tab for the battery unit; and a pouch having a space for accommodating the battery.

29. The lead tab for the secondary battery according to claim 15, wherein the insulation film comprises a film member and the magnetic member disposed in the film member.

30. The lead tab for the secondary battery according to claim 29, wherein each of the insulation film is melted and bonded to both of the metal lead and the other insulation film with a heat generation of the magnetic member by the alternating magnetic field.

31. The lead tab for the secondary battery according to claim 29, wherein the magnetic member comprises one of a metallic magnetic material, a ceramic-based magnetic material, or an oxide-based magnetic material.

32. The lead tab for the secondary battery according to claim 29, wherein the magnetic member is contained in the first and second insulation film in 0.01 to 50 mass percent.

Description

DESCRIPTION OF DRAWINGS

[0023] FIG. 1 is a schematic drawing showing a secondary battery including a lead tab according to an embodiment of the present invention.

[0024] FIG. 2 is a drawing showing a lead tab according to an embodiment of the present invention.

[0025] FIG. 3 is a drawing showing one side of an insulation film provided during manufacture of the lead tab shown in FIG. 2.

[0026] FIG. 4 is a flowchart schematically illustrating a manufacturing process of a lead tab according to an embodiment of the present invention.

[0027] FIGS. 5 to 8 are drawings for explaining a bonding process of a lead tab member during the manufacturing process of the lead tab shown in FIG. 4.

[0028] FIG. 9 is a cross-sectional drawing of a lead tab according to an embodiment of the present invention.

BEST MODE FOR INVENTION

[0029] Hereinafter, embodiments disclosed in the present specification will be described in detail with reference to the accompanying drawings, but the same or similar elements are assigned the same reference numerals regardless of the reference numerals, and redundant descriptions thereof will be omitted. The suffixes “module” and “unit” for the elements used in the following description are given or used interchangeably in consideration of only the ease of writing the specification, and do not have meanings or roles that are distinguished from each other by themselves. In addition, in describing the embodiments disclosed in the present specification, when it is determined that a detailed description of related known technologies may obscure the subject matter of the embodiments disclosed in the present specification, the detailed description thereof will be omitted. In addition, it should be noted that the accompanying drawings are for easy understanding of the embodiments disclosed in the present specification and should not be construed as limiting the technical spirit disclosed in the present specification by the accompanying drawings.

[0030] Also, when an element such as a layer, region or substrate is referred to as being “on” another component, it may be directly on another element or there may be an intermediate element between them.

[0031] The display device described herein may include a mobile phone, a smart phone, a laptop computer, a digital broadcasting terminal, a personal digital assistant (PDA), a portable multimedia player (PMP), a navigation system, and a slate PC, a Tablet PC, a Ultra Book, a digital TV, a desktop computer, etc. However, it will be readily apparent to those skilled in the art that the configuration according to the embodiment described in the present specification may be applied to a device capable of displaying even if it is a new product type to be developed later.

[0032] FIG. 1 is a schematic drawing showing a secondary battery including a lead tab according to an embodiment of the present invention. And FIG. 2 is a drawing showing a lead tab according to an embodiment of the present invention.

[0033] Referring to FIGS. 1 and 2, the secondary battery 1 may include a battery unit 10 and a pouch 20 having an accommodation space in which the battery unit 10 is accommodated.

[0034] Each of the electrode plates of the battery unit 10 may be electrically connected to one end of a positive terminal 11a and a negative terminal 11b, which are electrode terminals, to be drawn out.

[0035] A lead tab 30 may be connected to each of the positive terminal 11a and the negative terminal 11b. For example, the metal lead 32 of the positive lead tab 30a may be connected to the positive terminal 11a, and the metal lead 32 of the negative lead tab 30b may be connected to the negative terminal 11b. The lead tab 30 may be connected to the electrode terminals 11a and 11b by welding or the like, but is not limited thereto.

[0036] The metal lead 32 of the lead tab 30 has one end connected to the electrode terminals 11a and 11b, and the other end exposed to the outside of the sealing portion 21 formed at the edge of the pouch 20. The metal lead 32 may have a rectangular plate shape that is elongated in one direction.

[0037] The metal lead 32 connected to the positive terminal 11a may be made of aluminum, and the metal lead 32 connected to the negative terminal 11b may be made of copper, but is not limited thereto.

[0038] In addition, the lead tab 30 may be provided with an insulation film 35 bonded to both sides of the metal lead 32. The insulation film 35 may be elongated in a direction orthogonal to one direction of the metal lead 32.

[0039] The insulation film 35 has an insulating function while preventing the electrolyte filled in the pouch 20 from leaking to the outside.

[0040] The metal lead 32 and the insulation film 35 may be bonded to each other by being fused by heat.

[0041] In connection with the bonding of the metal lead 32 and the insulation film 35, in the related art, a technique for bonding the metal lead 32 and the insulation film 35 using a resistance heater has been proposed. Since the bonding time is excessively consumed, the overall process time is increased, and thus productivity may be lowered. In addition, when the temperature of the resistance heater is increased to shorten the bonding time, a problem of lowering adhesion due to deformation of the insulation film 35 may occur.

[0042] In addition, a technique for bonding the metal lead 32 and the insulation film 35 by induction heating (eg, high-frequency induction heating) on the surface of the metal lead 32 has been proposed, but since an additional process for bonding is required for bonding insulation films 35, there may also be a problem of lowering productivity due to an increase in the overall process time.

[0043] According to an embodiment of the present invention, since bonding between the metal lead 32 and the insulation film 35 and bonding between the insulation films 35 through induction heating can be performed simultaneously in a single process, it makes it possible to increase productivity according to the shortening of the process time.

[0044] Hereinafter, a lead tab according to an embodiment of the present invention and a manufacturing process thereof will be described in more detail with reference to FIGS. 3 to 9.

[0045] FIG. 3 is a drawing showing one side of an insulation film provided during manufacture of the lead tab shown in FIG. 2.

[0046] Referring to FIG. 3, the insulation film 35 may include a film member 36 and a magnetic member 37. For example, the insulation film 35 may have a thickness of about 100 to 150 micrometers and a width of 9 to 17 millimeters, but this may vary according to the standard of the lead tab 30.

[0047] The film member 36 may be implemented with a polymer synthetic resin such as polypropylene, polyethylene, a mixture thereof, or polyurethane. The film member 36 may be softened at about 50° C. to 90° C., and may be melted at about 100° C. to 170° C.

[0048] Depending on the embodiment, additives such as liquid paraffin-based, fatty acid ester-based, polyester-based, and polyglycerin-based may be added to the film member 36.

[0049] The magnetic member 37 may be formed in a powder form added or applied in the film member 36, but is not limited thereto. For example, the magnetic member 37 may be formed on one of both surfaces of the insulation film 35, but may be formed on both surfaces according to embodiments. When the magnetic member 37 is formed on the one surface, the one surface may correspond to a surface bonded to the metal lead 32 and another insulation film.

[0050] The magnetic member 37 may be implemented with an inorganic material that can be heated by an alternating magnetic field generated during induction heating. For example, the material can be implemented as such a metallic magnetic material such as iron (Fe), cobalt (Co), nickel (Ni), manganese bismuth (MnBi), samarium cobalt (SmCo5) or a ceramic-based magnetic material or an oxide-based magnetic material (ferrite), etc.

[0051] According to an embodiment, the magnetic member 37 may be contained in the insulation film 35 in about 0.01 to 50 mass percent (wt %). Preferably, the magnetic member 37 may be contained in the insulation film 35 in about 1 to 40 mass percent or about 5 to 30 mass percent.

[0052] According to an embodiment, in order to uniformly distribute the magnetic member 37 in the insulation film 35, an organic material such as a silane-based coupling agent may be treated on the surface of the magnetic member 37.

[0053] The magnetic member 37 generates heat by the alternating magnetic field, and the film member 36 is melted by the heat generation of the magnetic member 37, thereby being bonded to the metal lead 32 and the other insulation film 35.

[0054] That is, as the magnetic member 37 is provided in the insulation film 35, the metal lead 32 and the insulation film 35 can be bonded by induction heating, and the insulation films 35 can be bonded to each other. That is, when the lead tab 30 is manufactured, since the bonding process can perform only one induction heating, the process time can be effectively shortened and productivity can be improved.

[0055] Hereinafter, a manufacturing process of the lead tab 30 according to an embodiment of the present invention will be described with reference to FIGS. 4 to 8.

[0056] FIG. 4 is a flowchart schematically illustrating a manufacturing process of a lead tab according to an embodiment of the present invention. And FIGS. 5 to 8 are drawings for explaining a bonding process of a lead tab member during the manufacturing process of the lead tab shown in FIG. 4. And FIG. 9 is a cross-sectional view of a lead tab according to an embodiment of the present invention.

[0057] Referring to FIG. 4, the members (metal lead, insulation film) constituting the lead tab 30 are supplied to the manufacturing apparatus (S100), and a process of bonding the member using induction heating (eg, high frequency induction heating) may be performed (S110).

[0058] To this end, the manufacturing apparatus may be provided with an induction coil for induction heating the metal lead 32 and the magnetic member 37 by generating an alternating magnetic field.

[0059] Depending on the embodiment, before the bonding process (S110) is performed, a temporary bonding process of temporarily fusion may be further performed. Positioning and alignment of the metal lead 32 and the insulation films 35 may be performed by the temporary bonding process. Since positioning is performed by the temporary bonding process, it is possible to minimize the possibility of bubbles occurring between the insulation film 35 and the metal lead 32 or the insulation films 35 in the bonding process through induction heating.

[0060] Hereinafter, with reference to FIGS. 5 to 8, the bonding process (S110) will be described in more detail.

[0061] FIGS. 5 to 6 are drawings relating to a temporary bonding process. Depending on the embodiment, the lead tab manufacturing process may not include the temporary bonding process, and in this case, the processes of FIGS. 5 to 6 may be omitted.

[0062] Referring to FIGS. 5 and 6, the manufacturing apparatus may include a first heating head 500a and a second heating head 500b. The first heating head 500a and the second heating head 500b are components for a temporary bonding process of the metal lead 32, the first insulation film 35a, and the second insulation film 35b, for example, may include a resistance heater.

[0063] A first film suppling unit 510a may supply a first insulation film 35a to a lower side of the metal lead 32, and a second film suppling unit 510b may supply a second insulation film 35b to an upper side of the metal lead 32. The first film suppling unit 510a and the second film suppling unit 510b may be configured in the form of a reel in which the first insulation film 35a and the second insulation film 35b are wound, respectively. The first insulation film 35a and the second insulation film 35b may be the same as the insulation film 35 described above in FIG. 3.

[0064] For the temporary bonding process, the first film suppling unit 510a may supply the first insulation film 35a to a top of the first heating head 500a. The first insulation film 35a supplied to the first heating head 500a may be mounted on an upper surface of the first heating head 500a.

[0065] After the first insulation film 35a is supplied, the metal lead 32 may be seated on the first insulation film 35a. After the metal lead 32 is seated, the second film suppling unit 510b may supply the second insulation film 35b onto the metal lead 32 and the first insulation film 35a.

[0066] After the metal lead 32 and the insulation films 35a and 35b are put on the first heating head 500a, the first heating head 500a can be driven upward, and the second heating head 500b can be driven downwards. As the heating heads 500a and 500b are driven, the metal lead 32 and the insulation films 35a and 35b positioned between the first heating head 500a and the second heating head 500b may be pressed.

[0067] In addition, heat may be generated from a resistance heater provided in each of the first heating head 500a and the second heating head 500b. Heat generated from the resistance heater is conducted to the metal lead 32 and the insulation films 35a and 35b by thermal conduction, so that the metal lead 32 and the insulation films 35a and 35b may be heated.

[0068] The metal lead 32 and the insulation films 35a and 35b may be temporarily bonded (fused) by heating and pressing of the first heating head 500a and the second heating head 500b. As described above, since the bonding time is long in the case of bonding by thermal conduction, the temporary bonding process may be performed for a set time shorter than the time when the metal lead 32 and the insulation films 35a and 35b are completely bonded. Temporarily bonded metal leads 32 and insulation films 35a and 35b may be transferred to induction heating heads 700a and 700b (see FIG. 7).

[0069] Referring to FIG. 7, the manufacturing apparatus may include a first induction heating head 700a and a second induction heating head 700b.

[0070] The first induction heating head 700a may include a first head body 701a, a first induction coil 702a provided inside the first head body 701a, and a first elastic pad 703a provided on a surface of the first head body 701a facing the second induction heating head 700b.

[0071] The second induction heating head 700b may include a second head body 701b, a second induction coil 702b provided inside the second head body 701b, and a second elastic pad 703b provided on a surface of the second head body 701b facing the first induction heating head 700a.

[0072] The first induction coil 702a and the second induction coil 702b may emit an AC magnetic field as AC power is supplied.

[0073] In order for the magnetic member 37 of the metal lead 32 and the insulation film 35 to generate heat according to the emission of the AC magnetic field, the frequency and size of the AC power supplied to the induction coils 702a and 702b must be greater than or equal to a predetermined value. Based on this, for example, the frequency may be set to 10 kHz to 30 MHz. Preferably, the frequency may be set to 100 kHz to 10 MHz, or 100 kHz to 2 MHz. In addition, the size of the AC power may correspond to about 100 W to 50 kW, preferably 1 kW to 20 kW or 1 kW to 10 kW.

[0074] The first induction coil 702a and the second induction coil 702b may be implemented as a wire-shaped winding induction coil or a copper tube-shaped induction coil. When the induction coils 702a and 702b are implemented as wound induction coils, the frequency may be set to about 10 kHz to 200 kHz in order to minimize the effect of heat generation of the induction coil.

[0075] According to an embodiment, the first induction coil 702a and the second induction coil 702b may be connected to each other by a Litz wire or the like to be electrically energized. Accordingly, the first induction coil 702a and the second induction coil 702b may receive current at the same time. However, depending on the embodiment, the first induction coil 702a and the second induction coil 702b may be independently supplied/stopped with current.

[0076] In addition, according to an embodiment, the induction coil may be provided only in any one of the first induction heating head 700a and the second induction heating head 700b.

[0077] The first elastic pad 703a and the second elastic pad 703b are positioned to prevent direct contact between the head body 701a, 701b and the lead tab 30, or to prevent direct contact between the induction coils 702a and 702b and the lead tab 30, so any damage of the induction coil 702a, 702b or the lead tab 30 can be prevented.

[0078] The first elastic pad 703a and the second elastic pad 703b are in contact with the metal lead 32 and the insulation films 35a, 35b by vertical driving of the induction heating heads 700a, 700b, and the metal lead 32 and the insulation films 35a and 35b may be pressed for a predetermined time. For example, the pressure during the pressurization may be about 0.1 MPa to 1.5 MPa, but is not limited thereto.

[0079] The first elastic pad 703a and the second elastic pad 703b are implemented with a polymer-based material having elasticity to prevent damage to the metal lead 32 and the insulation films 35a, 35b when pressed. For example, the polymer may include silicone, fluorine, urethane, or synthetic rubber such as nitrile, chloroprene, or butyl.

[0080] As an example, the elastic pads 703a, 703b may have a thickness of about 0.1 mm to 5 mm, preferably 1 mm to 3 mm.

[0081] According to an embodiment, for smooth separation of the elastic pads 703a and 703b and the lead tab 30 after pressing, a releasing agent can be applied to a surface of the first elastic pad 703a and the second elastic pad 703b in contact with the metal lead 32 or the insulating films 35a, 35b. For example, the release agent may include a silicone or fluorine-based material.

[0082] Referring to FIG. 8, by driving the first induction heating head 700a and the second induction heating head 700b, the first elastic pad 703a and the second elastic pad 703b can press the metal lead 32 and the insulation film 35 (35a and 35b). In addition, the first induction coil 702a and the second induction coil 702b may emit an AC magnetic field as AC power is supplied.

[0083] By the alternating magnetic field emitted from the induction coils 702a and 702b, the metal lead 32 disposed in the heating region HR, and the magnetic member 37 of the insulation films 35 can be induction-heated. For example, the metal lead 32 and the insulation films 35 disposed in the heating region HR may be heated to about 100° C. to 300° C., but this is not necessarily the case.

[0084] As the metal lead 32 and the insulation film 35 are heated, the film member 36 may be melted and bonded to the metal lead 32, or may be bonded to a corresponding insulation film.

[0085] At this time, the elastic pads 703a, 703b may have a heat resistance temperature of −70° C. to 400° C., preferably 25° C. to 300° C. That is, since the elastic pads 703a and 703b have a heat resistance temperature higher than the melting temperature of the film member 36, they may not be deformed or melted when the metal lead 32 and the insulation films 35 are heated.

[0086] On the other hand, in order for the heating region HR to be formed to correspond to the insulation films 35, the first induction coil 702a and the second induction coil 702b may be disposed above or below the insulation films 35, but is not necessarily thereto.

[0087] In addition, a distance through which the alternating magnetic field emitted from the induction coils 702a and 702b is transmitted may be related to the frequency of the alternating current supplied to the induction coils 702a and 702b. That is, during the manufacturing process of the lead tab 30, by adjusting the frequency of the AC current supplied to the induction coils 702a and 70b to control the distance through which the AC magnetic field is transmitted, the size of the heating region HR can be adjusted to correspond to the insulation film 35.

[0088] Referring to FIG. 9, as the bonding process (S110) is performed, a portion of the first insulation film 35a may be bonded to a bottom of the metal lead 32, a portion of the second insulation film 35b may be bonded to an upper surface of the metal lead 32. In addition, the remaining portion of the first insulation film 35a may be bonded to each other with the remaining portion of the second insulation film 35b.

[0089] That is, a length L2 of the insulating films 35a and 35b may be formed longer than a width L1 of the metal lead 32 in the lead tab 30. Accordingly, the insulating films 35a and 35b can prevent a gap between the pouch 20 or the sealing part 21 and the metal lead 32 from occurring, and as a result, and can prevent the electrolyte from leaking to the outside. FIG. 4 will be described again.

[0090] After the bonding process (S110) of the metal lead 32 and the insulation films (35a, 35b) is performed, the lead tab 30 can be finally manufactured with through the shape restoration process (S120) and quality inspection (S130).

[0091] The shape restoration process (S120) can be a process for mitigating a physical deformation of the lead tab 30 caused by external force or heat during the bonding process (S110), and in particular, can correspond to the process of restoring the shape of both ends of the insulation film 35.

[0092] The lead tab 30 on which the shape restoration process (S120) has been completed may be confirmed whether or not it is normally manufactured through a quality inspection (S130).

[0093] According to an embodiment, when a defect of the lead tab 30 is detected, the cured film member 36 may be melted again through induction heating to perform the bonding process S110 again. That is, since the magnetic member 37 is formed on the insulation film 35, bonding to the lead tab 30 in which bonding failure has occurred can be easily performed again.

[0094] The above description is merely illustrative of the technical idea of the present invention, and those of ordinary skill in the technical field to which the present invention pertains can make various modifications and variations without departing from the essential characteristics of the present invention will be.

[0095] Accordingly, the embodiments disclosed in the present invention are not intended to limit the technical idea of the present invention, but to explain the technical idea, and the scope of the technical idea of the present invention is not limited by these embodiments.

[0096] The scope of protection of the present invention should be interpreted by the following claims, and all technical ideas within the scope equivalent thereto should be construed as being included in the scope of the present invention.