Secondary Battery Having Lead Film Including Luminous Material and Method of Inspecting Defects of Secondary Battery

Abstract

A secondary battery includes an electrode assembly configured to have a structure in which a separator is interposed between a positive electrode and a negative electrode, a battery case having formed therein a receiving portion configured to receive the electrode assembly, electrode leads configured to protrude outwards from the battery case, and lead films attached to opposite surfaces of each of the electrode leads, wherein each of the lead films includes a luminous material.

Claims

1. A secondary battery comprising: an electrode assembly configured to have a structure in which a separator is interposed between a positive electrode and a negative electrode; a battery case having formed therein a receiving portion configured to receive the electrode assembly; electrode leads configured to protrude outwards from the battery case; and lead films attached to opposite surfaces of each of the electrode leads, wherein each of the lead films comprises a luminous material.

2. The secondary battery according to claim 1, wherein the luminous material exhibits fluorescence by light irradiation.

3. The secondary battery according to claim 2, wherein the light irradiation is irradiation with ultraviolet light or blue light.

4. The secondary battery according to claim 1, wherein each of the lead films is configured to have a structure in which a lead film body and the luminous material are integrally formed.

5. The secondary battery according to claim 1, wherein each of the lead films is configured to have a structure comprising a lead film body and a luminous layer formed at an outer surface of the lead film body.

6. The secondary battery according to claim 1, wherein the luminous material includes one or more of an aqueous or solvent-based fluorescent dye, a sulfide-based fluorescent pigment, an oxysalt-based fluorescent pigment, or a phosphorescent pigment.

7. The secondary battery according to claim 1, wherein the luminous material includes one or more of a coumarin-based luminous material, a naphthalimide-based luminous material, a quinacridone-based luminous material, a cyanine-based luminous material, a xanthine-based luminous material, a pyridine-based luminous material, a low molecular weight luminous material, a high molecular weight luminous material, an inorganic-based luminous material, or a combination thereof.

8. The secondary battery according to claim 1, wherein each of the lead films comprises two or more luminous materials configured to emit different colors of light.

9. The secondary battery according to claim 1, wherein the electrode leads comprise a positive electrode lead and a negative electrode lead, and each of the lead films attached to the positive electrode lead and the negative electrode lead comprises two or more luminous materials configured to emit different colors of light.

10. The secondary battery according to claim 1, wherein each of the lead films comprises two or more luminous materials configured to emit different colors of light every predetermined length.

11. The secondary battery according to claim 1, wherein a protective layer is further added to an outer surface of each of the lead films.

12. A method of inspecting defects of the secondary battery according to claim 1, the method comprising: (a) irradiating the secondary battery with light; and (b) visually confirming whether a portion of the lead film fluoresces to determine whether the secondary battery is defective.

13. The secondary battery according to claim 4, wherein the luminous material is distributed in a composition of the lead film body.

14. The secondary battery according to claim 1, wherein the lead films attached to opposite surfaces of a first one of the electrode leads are configured to emit a first color of light, and the lead films attached to opposite surfaces of a second one of the electrode leads are configured to emit a second color of light that is different from the first color.

Description

DESCRIPTION OF DRAWINGS

[0044] FIG. 1 is a vertical sectional view showing a lead film according to an embodiment of the present invention.

[0045] FIG. 2 is a vertical sectional view showing a lead film according to another embodiment of the present invention.

[0046] FIG. 3 is a plan view showing a secondary battery according to an embodiment of the present invention.

[0047] FIG. 4 is a plan view showing a secondary battery according to another embodiment of the present invention.

[0048] FIGS. 5 and 6 are plan views of a secondary battery showing examples in which attachment of a lead film is defective.

BEST MODE

[0049] A secondary battery according to an embodiment of the present invention includes an electrode assembly configured to have a structure in which a separator is interposed between a positive electrode and a negative electrode, a battery case having formed therein a receiving portion configured to receive the electrode assembly, electrode leads configured to protrude outwards from the battery case, and lead films attached to opposite surfaces of each of the electrode leads, wherein each of the lead films includes a luminous material.

[0050] The structure of the electrode assembly is not particularly restricted. For example, the electrode assembly may be configured to have a stacked type structure, a jelly-roll type structure, a stacked/folded type structure, or a laminated/stacked type structure.

[0051] A laminate sheet constituting the battery case may be configured to have a structure including a first resin layer, which defines the inner surface of a main body of the battery case, a second resin layer, which defines the outer surface of the main body, and a metal layer, which is interposed between the first resin layer and the second resin layer.

[0052] The battery case is made of an aluminum laminate sheet, provides a space in which the electrode assembly is received, and generally has a pouch shape. The battery case is configured such that an outer resin layer, which is made of nylon or polyethylene terephthalate, is located outside a metal barrier layer, which is configured to prevent moisture permeation, and an inner resin layer, which is made of a polypropylene material and at which the battery case is thermally fused, is located inside the metal barrier layer.

[0053] The metal layer serves to prevent air, moisture, and the like from being introduced into the battery, and serves to securely support the battery case against physical force that may be generated inside and outside the battery during use or movement of the battery. The metal layer may be made of a metallic material, such as aluminum, an aluminum alloy, copper, a copper alloy, nickel, a nickel alloy, or stainless steel.

[0054] The first resin layer faces the surface of the battery case in which the electrode assembly and an electrolytic solution are received. For this reason, the first resin layer must be made of an insulative material capable of maintaining the state thereof insulated from the battery case during operation of the battery. In addition, durability of the first resin layer is required so as not to be torn or peeled off even when reacting with the electrolytic solution or contacting the electrode assembly.

[0055] The second resin layer serves to protect the battery from the outside. For this reason, the second resin layer must have high tensile strength and durability so as not to be easily peeled off or torn by external physical force such that the metal layer located inside the second resin layer is not exposed.

[0056] The first resin layer and the second resin layer may be made of the same material or different materials. Since the laminate sheet is sealed by thermal fusion, the first resin layer is made of a material that is melted and fused when pressed at high temperature.

[0057] The lead film is constructed using one or more selected from the group consisting of polyimide (PI), polypropylene (PP), polyethylene (PE), polyethylene terephthalate (PET), polyvinyl chloride (PVC), high density polyethylene (HDPE), and an epoxy resin, and is bonded to the inner layer of the battery case by thermal fusion using heat and pressure.

[0058] The kind of the luminous material is not particularly restricted as long as the luminous material is a material that is excited by ultraviolet light and blue light to emit light having a wavelength band that can be discriminated with the naked eye. Preferably, however, a heat-resistant material that is not damaged at a temperature of at least 100 C. or more so as not to be deteriorated in the thermal fusing process during manufacture of the secondary battery is used as the luminous material.

[0059] The luminous material may be one or more selected from the group consisting of an aqueous or solvent-based fluorescent dye, a sulfide-based fluorescent pigment, an oxysalt-based fluorescent pigment, and a phosphorescent pigment.

[0060] In addition, the luminous material may be one or more selected from the group consisting of a coumarin-based luminous material, a naphthalimide-based luminous material, a quinacridone-based luminous material, a cyanine-based luminous material, a xanthine-based luminous material, a pyridine-based luminous material, a low molecular weight luminous material, a high molecular weight luminous material, an inorganic-based luminous material, and a combination thereof.

[0061] Specifically, the luminous material may be one or more selected from the group consisting of a coumarin-based luminous material including 3-(2-benzothiazolyl)-7-diethylamino coumarin (coumarin 6), 3-(2-benzimidazolyl)-7-diethylamino coumarin (coumarin 7), and coumarin 135; a naphthalimide-based luminous material including solvent yellow 43 and solvent yellow 44; a quinacridone-based luminous material such as diethyl quinacridone (DEQ); a cyanine-based luminous material including 4-dicyanomethylene-2-methyl-6-(p-dimethylaminostyryl)-4H-pyran(DCM-1(I)), DCM-2(II), and DCJTB(III); a xanthine-based luminous material including rhodamine B and rhodamine 6G; a pyridine-based luminous material including pyridine 1; a low molecular weight luminous material such as 4,4-difluoro-1,3,5,7-tetraphenyl-4-bora-3a,4a-diaza-s-indacene (IV), lumogen F red, and nile red (V); a high molecular weight luminous material including polyphenylene, polyarylene, and polyfluorene; an inorganic-based luminous material such as Sr(PO2)Cl:Eu emitting blue light, Zn2GeO2:Mn emitting green light, and Y2O2S:Eu emitting red light; and a combination thereof.

[0062] In addition, a rare-earth element, which is a nonmetal material including no conductive metal, may be used as the luminous material in order to secure insulation of the secondary battery, and thulium (Tm), neodymium (Nd), ytterbium (Yb), and gadolinium (Gd) may be included.

[0063] The lead film may be configured to have a structure in which a lead film body and the luminous material are integrally formed. Specifically, at the time of manufacturing the lead film, the luminous material is distributed in a lead film composition in order to form the lead film.

[0064] In addition, the lead film may be configured to have a structure including a lead film body and a luminous layer formed at the outer surface of the lead film body. The lead film body means a conventional lead film. Specifically, the luminous material is coated or sprayed on the surface of the lead film body, or a film including the luminous material is attached to the outer surface of the lead film body in order to form a luminous layer formed at the outer surface of the lead film body.

[0065] A protective layer is further added to the outer surface of the lead film or the luminous layer.

[0066] The protective layer serves to prevent the luminous material from being separated from the lead film or to prevent the luminous layer from being damaged. Since the protective layer allows the lead film to be uniformly luminescent, it is possible to minimize errors in inspecting defects of the secondary battery.

[0067] In addition, the protective layer serves to increase the strength of the lead film, thereby preventing the lead film from being rolled or wrinkled at the time of thermal fusion.

[0068] The protective layer may be made of a material that is capable of absorbing light without reflecting the light such that the light is incident on the luminous layer and thus the luminous layer can fluoresce.

[0069] The protective layer is bonded to the inner layer of the battery case by thermal fusion using heat and pressure. In order to secure insulation and sealability with the battery case, the protective layer may be made of one or a mixture of two or more selected from the group consisting of polyimide (PI), polypropylene (PP), polyethylene (PE), polyethylene terephthalate (PET), polyvinyl chloride (PVC), high density polyethylene (HDPE), and an epoxy resin, in the same manner as the lead film.

[0070] In the case in which the lead film is configured to have a multilayer structure including a lead film body, a luminous layer, and a protective layer, adhesive layers may be formed and adhered between the lead film body and the luminous layer and between the luminous layer and the protective layer. Alternatively, the lead film may be configured to have a multilayer structure in which a plurality of layers is formed in the shape of a film through pneumatic protrusion so as to be directly adhered to each other without separate adhesive layers.

[0071] The lead film is configured to have a structure including two or more kinds of luminous materials that emit different colors of light. Specifically, the lead film may include a first luminous portion configured to emit green light, a second luminous portion configured to emit red light, and a third luminous portion configured to emit blue light.

[0072] The present invention also provides a method of inspecting defects of the secondary battery.

[0073] Specifically, the method of inspecting defects of the secondary battery may include:

[0074] (a) a step of applying a lead film configured to have a structure including a luminous material to manufacture a secondary battery;

[0075] (b) a step of irradiating the secondary battery manufactured at step (a) with light; and

[0076] (c) a step of confirming a portion of the lead film that fluoresces with the naked eye to determine whether the secondary battery is defective.

[0077] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings such that the preferred embodiments of the present invention can be easily implemented by those skilled in the art to which the present invention pertains. In describing the principle of operation of the preferred embodiments of the present invention in detail, however, a detailed description of known functions and configurations incorporated herein will be omitted when the same may obscure the subject matter of the present invention.

[0078] In addition, the same reference numbers will be used throughout the drawings to refer to parts that perform similar functions or operations. In the case in which one part is said to be connected to another part in the specification, not only may the one part be directly connected to the other part, but also, the one part may be indirectly connected to the other part via a further part. In addition, that a certain element is included does not mean that other elements are excluded, but means that the other elements may be further included unless mentioned otherwise.

[0079] Embodiments of the present invention will be described in detail with reference to the accompanying drawings.

Embodiment 1

[0080] FIG. 1 is a vertical sectional view showing a lead film according to an embodiment of the present invention.

[0081] Referring to FIG. 1, the lead film 10 according to this embodiment is configured to have a single-layer structure. Specifically, the lead film is configured to have a structure in which a lead film body 11 and a luminous material 12 are integrally formed.

Embodiment 2

[0082] FIG. 2 is a vertical sectional view showing a lead film according to another embodiment of the present invention.

[0083] Referring to FIG. 2, the lead film 20 according to this embodiment is configured to have a two-layer structure in which a luminous layer 22 is formed on one surface of a lead film body 21. Preferably, therefore, when lead films are attached to opposite surfaces of an electrode lead, the lead film body is located so as to face the electrode lead, and the luminous layer is located so as to be attached to the other surface of the lead film body that faces the electrode lead.

[0084] Unlike what is shown in FIGS. 1 and 2, protective layers (not shown) may be selectively added to outer surfaces of the lead film 10 and the luminous layer 22.

[0085] According to another embodiment of the present invention, a lead film includes two or more kinds of luminous materials configured to emit different colors of light. Specifically, the lead film includes a first luminous portion configured to emit green light, a second luminous portion configured to emit red light, and a third luminous portion configured to emit blue light. The luminous portion means a luminous material formed integrally with the lead film body or a luminous layer formed on the upper surface of the lead film body.

[0086] The first luminous portion, the second luminous portion, and the third luminous portion are not limited to the green light, the red light, and the blue light, respectively. The luminous portions may be configured to emit other different colors of light, such as yellow light or orange light, in addition to the green light, the red light, and the blue light. In addition, the luminous portions may be configured to emit a single color of light. In the case in which the luminous portions are configured to emit a single color of light, the luminous portions may have different degrees of brightness depending on the quantity of a luminous material.

Embodiment 3

[0087] FIG. 3 is a plan view showing a secondary battery according to an embodiment of the present invention.

[0088] Referring to FIG. 3, an electrode assembly 140 is received in a receiving portion 120 formed in the central part of a pouch-shaped battery case 110. A positive electrode lead 151 and a negative electrode lead 152 are formed at the upper part of the electrode assembly 140. A lead film 160 including a first luminous portion 162 is attached to each of the upper and lower surfaces of the positive electrode lead 151, and a lead film 170 including a second luminous portion 172 is attached to each of the upper and lower surfaces of the negative electrode lead 152.

[0089] The lead films 160 and 170, which include luminous portions 162 and 172 configured to emit different colors of light, respectively, are attached to the positive electrode lead 151 and the negative electrode lead 152, respectively, whereby it is possible to distinguish between a positive electrode and a negative electrode based on the colors of light of the lead films 160 and 170. When a battery module or a battery pack including a plurality of battery cells is constructed, therefore, it is possible to easily distinguish between electrodes for series connection or parallel connection of the battery cells.

Embodiment 4

[0090] FIG. 4 is a plan view showing a secondary battery according to another embodiment of the present invention.

[0091] Referring to FIG. 4, a first luminous portion 261, a second luminous portion 262, and a third luminous portion 263, which are configured to emit different colors of light, are formed at a lead film 260.

[0092] Specifically, the first luminous portion 261, which is configured to emit green light, the second luminous portion 262, which is configured to emit red light, and the third luminous portion 263, which is configured to emit blue light, are formed from the protruding distal end of the lead film 260 toward a battery case 210. According to the above construction, it is possible to grasp the protruding length of the lead film 260 based on the region that is confirmed with the naked eye after a secondary battery is manufactured.

[0093] Specifically, it is preferable that 15% to 30% of the total length of the lead film 260 protrude and 50% or more not protrude. The first luminous portion 261 may be formed from the protruding distal end of the lead film 260 so as to reach a 15% point toward the battery case 210, and the second luminous portion 262 may be formed from the protruding distal end of the lead film 260 so as to be located between a 10% point and a 40% point toward the battery case 210.

[0094] In the case in which the lead film 260 is exposed outwards from the battery case 210 up to the part at which the second luminous portion 262 is formed, as shown in FIG. 4, there are no parts of the positive electrode lead 251 and the negative electrode lead 252 that directly contact the battery case 210 when the outer circumferential surface of the battery case is sealed. After the secondary battery is manufactured, therefore, it can be seen that the protruding length of the lead film 260 is within a normal range in the case in which the second luminous portion 262 is confirmed with the naked eye.

[0095] FIGS. 5 and 6 are plan views of the secondary battery showing examples in which attachment of the lead film is defective.

[0096] In the case in which the lead film 260 protrudes outwards from the battery case 210 up to the part at which the first luminous portion 261 is formed and the second luminous portion 262 does not protrude, as shown in FIG. 5, it can be seen that the protruding length is insufficient. In the above case, there are no parts of the positive electrode lead 251 and the negative electrode lead 252 that directly contact the battery case 210 when the outer circumferential surface of the battery case 210 is sealed, but the protruding length is too short, whereby the lead film may be rolled or bent during a thermal fusion sealing process.

[0097] In the case in which the lead film protrudes outwards from the battery case up to the part at which the third luminous portion is formed, as shown in FIG. 6, the negative electrode lead and the positive electrode lead directly contact the battery case, whereby problems, such as deterioration of insulation, occurrence of short circuit, or corrosion, may result. In the case in which even the third luminous portion is seen, therefore, the protruding length of the lead film is excessive, whereby it can be seen that the lead film is defective.

[0098] Although the preferred embodiments of the present invention have been described by way of illustration, the scope of the present invention is not limited to the specific embodiments described herein, and the present invention can be appropriately modified within the category described in the claims.

DESCRIPTION OF REFERENCE NUMERALS

[0099] 10, 20, 160, 170, 260: Lead films [0100] 11, 21, 161, 171: Lead film bodies [0101] 12: Luminous material [0102] 22: Luminous layer [0103] 100, 200: Pouch-shaped secondary batteries [0104] 110, 210: Battery cases [0105] 120, 220: Receiving portions [0106] 130, 230: Sealed portions [0107] 140, 240: Electrode assemblies [0108] 150, 250: Electrode leads [0109] 151, 251: Positive electrode leads [0110] 152, 252: Negative electrode leads [0111] 162, 261: First luminous portions [0112] 172, 262: Second luminous portions [0113] 263: Third luminous portion

INDUSTRIAL APPLICABILITY

[0114] As is apparent from the above description, a pouch-shaped secondary battery according to an embodiment of the present invention is configured such that a protruding portion of a lead film fluoresces by light irradiation. Since the portion of the lead film that fluoresces is confirmed with the naked eye after the secondary battery is manufactured and thus the attached state of the lead film is easily confirmed, it is possible to secure insulation of the secondary battery and to easily sort defective products in advance, whereby it is possible to improve reliability.

[0115] In addition, lead films attached to a positive electrode lead and a negative electrode lead each include two or more luminous materials configured to emit different colors of light, whereby it is possible to distinguish between the positive electrode and the negative electrode based on the colors of light of the lead films. When a battery module or a battery pack including a plurality of battery cells is constructed, therefore, it is possible to easily distinguish between electrodes for series connection or parallel connection of the battery cells.

[0116] Each of the lead films includes two or more luminous materials configured to emit different colors of light every predetermined length. When confirming with the naked eye by light irradiation, it is possible to easily grasp the protruding length of each of the lead films based on luminous colors. That is, it is possible to easily grasp a range within which each of the lead films excessively protrudes outwards from a battery case or does not too little protrude outwards from the battery case with the naked eye.

[0117] A protective layer is further added to the outer surface of each of the lead films, whereby it is possible to prevent the luminous material from being separated from each of the lead films or to prevent a luminous layer from being damaged. Since each of the lead films is uniformly luminescent, it is possible to minimize errors in inspecting defects of the secondary battery. In addition, the protective layer increases the strength of each of the lead films, thereby preventing each of the lead films from being rolled or wrinkled at the time of thermal fusion.

[0118] In the pouch-shaped secondary battery according to the embodiment of the present invention, as described above, it is possible to easily confirm whether the lead films are attached to correct positions, whereby it is possible to improve insulation of the secondary battery and to accurately and rapidly determine defective products by light irradiation.