ICB(Inter-Connection Board) Busbar Assembly Structure And ICB Assembly Including The Same

Abstract

An ICB busbar assembly structure and an ICB assembly including the same are disclosed. An ICB (Inter-Connection Board) busbar assembly structure according to an embodiment of the present invention comprises: an ICB housing covering the front and rear of a battery cell stacking portion; a busbar electrically connected to an electrode lead tab exposed from the battery cell stacking portion; and an assembly hook portion disposed on the front of the ICB housing and mechanically coupled to assembly grooves (134a, 134b) formed on the upper and lower parts of the busbar, respectively, to fix the position.

Description

Technology Field

[0001] The present invention relates to an ICB busbar assembly structure and an ICB assembly including the same, and more specifically, to an ICB busbar assembly structure for the smooth fabrication (assembly) of a battery module / pack and an ICB assembly including the same. Background Technology

[0002] Generally, when manufacturing a battery module, an ICB (Inter-Connection Board) block is installed to electrically connect the multiple battery cells assembled on the front and rear sides.

[0003] Figure 1 shows a busbar assembly structure applied to a conventional ICB and the assembly state of a battery cell electrode lead using the same.

[0004] Figure 2 shows the structure of a busbar applied to a conventional ICB.

[0005] Referring to FIGS. 1 and 2, the ICB (1) used in the assembly of a conventional battery module has the upper and lower parts of a busbar (3) connected to a sensing board (Printed Circuit Board, PCB) configured on the inside through a heat welding structure (4). Then, the positive lead tab (2a) and negative lead tab (2b) of a battery cell (2) drawn out to the front of the ICB (1) are connected to the connected busbar (3) in a bending manner, forming a structure.

[0006] The ICB (1) is formed such that, in order to connect electrode leads (2a, 2b) corresponding to a plurality of battery cells (2), a plurality of busbars (3) are assembled into a heat-welded structure (4) using a heat welding machine and are structured to allow insert injection. Additionally, the busbars (3) have upper holes (h1) and lower holes (h2) formed for the heat-welded structure (4).

[0007] However, the bus bar (3) assembled in the conventional ICB (1) has a narrow gap between the heat welding structure (4) and the protruding lead tabs (2a, ab), so there is a concern that there may be structural interference during welding and bending assembly, which could lead to defects.

[0008] At this time, if an interference avoidance structure is applied to widen the gap between the upper and lower heat welding structure (4) and the lead tabs (2a, ab) of the bus bar (3), that is, if the upper hole (h1) and the lower hole (h2) are widened further, the overall size (length) of the bus bar (3) increases, which has the disadvantage of increasing material costs. However, if the size of the bus bar (3) is minimized, the gap between the heat welding structure (4) and the lead tabs (2a, ab) narrows, causing interference with each other and resulting in a problem of quality degradation in the welding process and the bending process.

[0009] In addition, the conventional method of manufacturing a busbar (3) involves a first step (S1) of feeding material into a press, a second step (S2) of pressing the material, a third step (S3) of processing an upper hole (h1) and a lower hole (h2) through drilling in the pressed material, and a fourth step (S4) of trimming unnecessary parts such as corners. However, the busbar (3) of the conventional ICB (1) has a structure in which an upper hole (h1) and a lower hole (h2) are formed for heat welding and insertion, which has the disadvantage of requiring an additional manufacturing process.

[0010] The matters described in this background technology section are written to enhance understanding of the background of the invention and may include matters that are not prior art already known to those skilled in the art to which this technology belongs. The problem to be solved

[0011] An embodiment of the present invention aims to provide an ICB (Inter-Connection Board) busbar assembly structure and an ICB assembly including the same, which are applied to electric vehicle batteries to electrically connect a large number of battery cells, by manufacturing the ICB busbar in a hook-type assembly structure to solve the problem of interference with electrode lead tabs and simplify the busbar assembly process. means of solving the problem

[0012] According to one aspect of the present invention, an ICB busbar assembly structure comprises: an ICB housing covering the front and rear of a battery cell stack; a busbar electrically connected to an electrode lead tab exposed from the battery cell stack; and an assembly hook portion disposed on the front of the ICB (Inter-Connection Board) housing and mechanically coupled to assembly grooves (134a, 134b) formed on the upper and lower parts of the busbar, respectively, to fix the position.

[0013] In addition, the assembly hook portions can be arranged respectively, taking into account the number and location of the busbars installed in the ICB housing.

[0014] Additionally, the busbar may include an upper assembly groove machined with a concave cross-sectional shape along the width direction of the upper surface; and a lower assembly groove machined with a concave cross-sectional shape along the width direction of the lower surface.

[0015] Additionally, the assembly hook portion may include an upper hook processed into a hook shape that fits into the upper assembly groove; and a lower hook processed into a hook shape that fits into the lower assembly groove.

[0016] In addition, either of the upper hook or the lower hook can be installed to be movable in the vertical direction through a guide groove.

[0017] Additionally, the busbar can be assembled by engaging the upper assembly groove of the busbar with the upper hook positioned in the ICB housing during assembly, and then, with the lower hook retracted along the guide groove, lowering the lower assembly groove of the busbar to be seated in the ICB housing, after which the lower hook advances to engage with the lower assembly groove.

[0018] In addition, the busbar may be manufactured by including the steps of: feeding a material into an extrusion molding machine; creating an upper assembly groove and a lower assembly groove extruded product along the width direction through the extrusion molding machine; and trimming the extruded product to a certain width length to create a plurality of.

[0019] In addition, the upper hook and the lower hook are made of a shape-memory elastic material, and after the bus bar is assembled with at least one of them spread outward, they are restored to their original shape to fix the assembled position.

[0020] Meanwhile, according to one aspect of the present invention, an ICB assembly comprises an ICB busbar assembly structure as described in any one of the above claims.

[0021] Additionally, it may further include an electrode insertion opening that penetrates the ICB housing to expose the positive lead tab and negative lead tab of each battery cell to the outside; and a bending guide part attached to the inner wall of the electrode insertion opening to guide the insertion path of each lead tab without interference with the internal structure.

[0022] In addition, the bending guide portion can form a gentle slope that covers the stepped portion formed on the inner wall of the electrode insertion opening, thereby guiding the positive lead tab and the negative lead tab so that they do not get caught on the stepped portion when inserted. Effects of the invention

[0023] According to an embodiment of the present invention, by assembling the ICB busbar in a hook format, the manufacturing process can be simplified compared to a conventional heat-welded busbar, and the conventional heat-welding process can be omitted, thereby resolving the interference problem with the electrode lead tab and simplifying the busbar assembly process.

[0024] In addition, by omitting the upper and lower holes (h1 / h2) required for conventional heat welding during the manufacturing of the busbar, the overall size can be reduced, thereby reducing material costs.

[0025] In addition, by forming a banding guide that surrounds the stepped portion formed within the electrode insertion hole, it is possible to expect the effect of facilitating the exposure of the lead electrode and the banding operation of the battery cell assembly battery cell stacking portion during the assembly of the ICB. Brief explanation of the drawing

[0026] Figure 1 shows a busbar assembly structure applied to a conventional ICB and the assembly state of a battery cell electrode lead using the same. Figure 2 shows the structure of a busbar applied to a conventional ICB. Figure 4 shows the configuration of an ICB assembly for manufacturing a battery module according to an embodiment of the present invention. FIG. 5 shows an improved busbar structure assembled to an ICB assembly according to an embodiment of the present invention. FIGS. 6 and 7 show a side cross-sectional view along line AA and a plan cross-sectional view along line BB of FIG. 4 according to an embodiment of the present invention. FIG. 8 is a flowchart showing a method for manufacturing a busbar (134) according to an embodiment of the present invention. Figure 9 shows a comparison of the size of a busbar according to an embodiment of the present invention and a conventional busbar. Specific details for implementing the invention

[0027] Below, embodiments of the present invention are described in detail with reference to the attached drawings so that those skilled in the art can easily implement the invention.

[0028] The terms used herein are for the purpose of describing specific embodiments only and are not intended to limit the invention. As used herein, singular forms are intended to include plural forms as well, unless explicitly otherwise indicated in the context. It will also be understood that the terms “include” and / or “include,” as used herein, specify the presence of the mentioned features, integers, steps, operations, components and / or components, but do not exclude the presence or addition of one or more of other features, integers, steps, operations, components, components and / or groups thereof. As used herein, the term “and / or” includes any one or all combinations of the items listed in association.

[0029] Throughout the specification, terms such as first, second, A, B, (a), (b), etc., may be used to describe various components, but said components shall not be limited by said terms. These terms are intended only to distinguish a component from other components, and the nature, order, or sequence of said component is not limited by said terms.

[0030] Throughout the specification, when it is stated that one component is 'connected' or 'joined' to another component, it should be understood that it may be directly connected to or joined to that other component, or that there may be other components in between. On the other hand, when it is stated that one component is 'directly connected' or 'directly joined' to another component, it should be understood that there are no other components in between.

[0031] Throughout the specification, the terms used are merely for describing specific embodiments and are not intended to limit the invention. Singular expressions include plural expressions unless the context clearly indicates otherwise.

[0032] Additionally, it is understood that one or more of the methods or aspects thereof described below may be executed by at least one controller. The term "controller" may refer to a hardware device comprising memory and a processor. The memory is configured to store program instructions, and the processor is specifically programmed to execute program instructions to perform one or more processes described in more detail below. The controller may control the operation of units, modules, components, devices, or similar things as described herein. Furthermore, it is understood that the methods below may be executed by a device comprising a controller together with one or more other components, as recognized by those skilled in the art.

[0033] Now, an ICB busbar assembly structure according to an embodiment of the present invention and an ICB assembly including the same will be described in detail with reference to the drawings.

[0034] The present invention relates to an ICB busbar assembly structure and an ICB assembly including the same, and more specifically, to an ICB busbar assembly structure and an ICB assembly including the same that is applied to an electric vehicle battery to electrically connect a large number of battery cells.

[0035] First, FIG. 3 schematically shows the configuration of a battery module according to an embodiment of the present invention.

[0036] Referring to FIG. 3, a battery module (100) according to an embodiment of the present invention includes a battery cell stacking portion (110), a battery case (120), and an ICB (Inter-Connection Board) assembly (130, commonly referred to as an ICB block).

[0037] The battery module (100) is assembled on a factory production line and completed as a battery system assembly (Battery System Assembly, BSA) packaged in a battery pack case (Battery Pack Case, BPC) and installed in an electric vehicle (xEV).

[0038] The battery cell stacking section (110) is configured by stacking a plurality of battery cells (111) according to the required capacity. The battery cells (111) are manufactured by cross-stacking a certain number of positive (+) electrodes, negative (-) electrodes, and separators according to the determined capacity, and then storing and sealing them in a pouch or can. The battery cells (111) include a positive lead tab (112a) and a negative lead tab (112b) that are extended in the longitudinal direction at the front and rear, respectively, and these can be collectively defined as electrode lead tabs (112).

[0039] The battery case (120) has a rectangular assembly structure including a lower frame (121), a top cover (122), and an end plate (123), thereby housing a battery cell stack (110) inside.

[0040] Figure 4 shows the configuration of an ICB assembly for manufacturing a battery module according to an embodiment of the present invention.

[0041] FIG. 5 shows an improved busbar structure assembled to an ICB assembly according to an embodiment of the present invention.

[0042] FIGS. 6 and 7 show a side cross-sectional view along line AA and a plan cross-sectional view along line BB of FIG. 4 according to an embodiment of the present invention.

[0043] Referring to FIGS. 4 to 7, an ICB assembly (130) for manufacturing a battery module (100) according to an embodiment of the present invention includes an ICB housing (131) covering the front and rear of a battery cell stack (110), a bus bar (134) electrically connected to an electrode lead tab (112) exposed from each battery cell (111) of the battery cell stack (110), and an assembly hook portion (133) mechanically coupled to assembly grooves (134a, 134b) formed on the upper and lower parts of the bus bar (134) to fix the position.

[0044] In addition, the ICB assembly (130) may further include an electrode insertion opening (132) that penetrates the ICB housing (131) to expose the positive lead tab (112a) and negative lead tab (112b) of each battery cell (111) to the outside, and a bending guide part (135) attached to the inner wall of the electrode insertion opening (132) to guide the insertion path (i.e., penetration path) of each lead tab (112a or 112b) without interference with the internal structure.

[0045] The assembly hook portion (133) is arranged in each case considering the number and location of busbars (134) installed in the ICB housing (131).

[0046] The busbar (134) includes an upper assembly groove (134a) machined with a concave cross-sectional shape along the width direction (x-axis) of the upper surface and a lower assembly groove (134b) machined with a concave cross-sectional shape along the width direction (x-axis) of the lower surface.

[0047] The assembly hook portion (133) includes an upper hook (133a) machined into a hook shape that fits into the upper assembly groove (134a) and a lower hook (133b) machined into a hook shape that fits into the lower assembly groove (134b).

[0048] The assembly hook portion (133) can be implemented to secure the busbar (134) in various ways.

[0049] For example, either the upper hook (133a) or the lower hook (133b) of the assembly hook portion (133) may be installed to be movable in the vertical direction through the guide groove (136). For example, the upper assembly groove (134a) of the bus bar (134) may be coupled to the upper hook (133a) positioned in the ICB housing (131), and the lower assembly groove (134b) of the bus bar (134) may be lowered and seated in the ICB housing (131) while the lower hook (133b) is retracted along the guide groove (136), after which the lower hook (133b) may advance and be coupled with the lower assembly groove (134b). At this time, the lower hook (133b) may be fixed so that it is caught on the ICB housing (131) in the coupled state and does not get pushed back.

[0050] Additionally, embodiments of the present invention are not limited thereto, and the upper hook (133a) and the lower hook (133b) may be provided with a shape-memory elastic material. Accordingly, the upper hook (133a) and the lower hook (133b) may be restored to their original shape after the bus bar (134) is assembled with at least one of them spread outward, thereby fixing the assembled position.

[0051] Meanwhile, when manufacturing a battery module (100), if the ICB assembly (130) is assembled at the front or rear of the case where the battery cell stacking section (110) is located, a large number of positive lead tabs (112a) and negative lead tabs (112b) must be exposed to the outside, corresponding to the number of battery cells (111) present in the battery cell stacking section (110).

[0052] At this time, the positive lead tab (112a) and the negative lead tab (112b) must pass through a narrow electrode insertion opening (132) such as a slot structure. During the manufacturing process of the battery cells (111), the positive lead tab (112a) and the negative lead tab (112b) do not have a consistently straight shape and are bent in various directions, making assembly difficult. In addition, as shown in FIG. 7, a step portion (137) is formed on the inner side of the electrode insertion opening (132) due to a bus bar (134) installed in a prior process, so when inserting the electrode lead tab (112), the end gets caught or folded, acting as an obstacle.

[0053] Accordingly, the banding guide portion (135) according to the embodiment of the present invention forms a gentle slope that covers the stepped portion formed on the inner wall of the electrode insertion opening (132) so as not to get caught when inserting the positive lead tab (112a) and the negative lead tab (112b).

[0054] Therefore, when assembling the ICB assembly (130) to the battery cell stack (110), it has the effect of facilitating the exposure of the positive lead tab (112a) and the negative lead tab (112b) and the banding operation to attach to the bus bar (134).

[0055] Meanwhile, FIG. 8 is a flowchart showing a method for manufacturing a busbar (134) according to an embodiment of the present invention.

[0056] Referring to FIG. 8, the method for manufacturing a bus bar (134) according to an embodiment of the present invention comprises a total of three steps, including: a step of feeding a material into an extrusion molding machine (process) (S10); a step of creating an extruded product in which an upper assembly groove (134a) and a lower assembly groove (134a) are formed along the width direction (x-axis) through the extrusion molding machine (process) (S20); and a step of creating a plurality of bus bars (134) by trimming the extruded product to a predetermined width length (S30).

[0057] In contrast, as previously explained, the conventional method of manufacturing a busbar (3) is produced through a total of four steps, including a first step (S1) of feeding material into a press, a second step (S2) of pressing the material, a third step (S3) of processing an upper hole (h1) and a lower hole (h2) through drilling in the pressed material, and a fourth step (S4) of trimming unnecessary parts such as corners.

[0058] Accordingly, the method for manufacturing a busbar (134) according to an embodiment of the present invention has the advantage of being able to omit the additional process of the third step (S3), which involves processing an upper hole (h1) and a lower hole (h2) through drilling in the pressed material, compared to the conventional method for manufacturing a busbar (3) described above. In addition, the conventional heat welding process can be omitted when assembling the busbar, thereby resolving the interference problem with the lead tab and simplifying the busbar assembly process.

[0059] Meanwhile, FIG. 9 shows a comparison of the size of a busbar according to an embodiment of the present invention and a conventional busbar.

[0060] Referring to FIG. 9, the conventional bus bar (3) has a narrow gap between the heat welding structure (4) and the protruding lead tabs (2a, ab), which may cause structural interference during welding and bending assembly and potentially lead to defects. Additionally, when the gap between the upper / lower holes (h1 / h2) required for heat welding of the bus bar (3) and the lead tabs (2a, ab) is widened, there is a problem that the overall size (length) of the bus bar (3) increases.

[0061] In contrast, the bus bar (134) according to the embodiment of the present invention does not require conventional heat welding, so the size can be reduced by omitting (deleting) the upper / lower holes (h1 / h2).

[0062] As such, according to an embodiment of the present invention, by assembling the ICB busbar in a hook form, the manufacturing process can be simplified compared to a conventional heat-welded busbar, and the conventional heat-welding process can be omitted, thereby resolving the interference problem with the lead tab and simplifying the busbar assembly process.

[0063] In addition, by omitting the upper and lower holes (h1 / h2) required for conventional heat welding during the manufacturing of the busbar, the overall size can be reduced, thereby reducing material costs.

[0064] In addition, by forming a banding guide that surrounds the stepped portion formed within the electrode insertion hole, it is possible to expect the effect of facilitating the exposure of the lead electrode and the banding operation of the battery cell assembly battery cell stacking portion during the assembly of the ICB.

[0065] Although embodiments of the present invention have been described in detail above, the scope of the present invention is not limited thereto, and various modifications and improvements by those skilled in the art using the basic concept of the present invention as defined in the following claims also fall within the scope of the present invention. Explanation of the symbols

[0066] 100: Battery module 110: Battery cell stacking section 120: Battery Case 111: Battery cell 112: Electrode Lead Tab 112a, 112b: Positive lead tab, Negative lead tab 130: ICB assembly 131: ICB Housing 132: Electrode insertion port 133: Assembly hook part 133a: 133b: Top hook, bottom hook 134: Busbar 134a, 134b: Top assembly groove, bottom assembly groove 135: Banding guide section 136: Guide Home 137: Step section

Claims

Claim 1 An ICB (Inter-Connection Board) assembly structure comprising: an ICB housing covering the front and rear of a battery cell stacking section; a busbar electrically connected to an electrode lead tab exposed from the battery cell stacking section; and an assembly hook portion disposed on the front of the ICB housing and mechanically coupled to assembly grooves (134a, 134b) formed on the upper and lower parts of the busbar, respectively, to fix its position, wherein the busbar comprises an upper assembly groove machined with a concave cross-sectional shape along the width direction of the upper surface; and a lower assembly groove machined with a concave cross-sectional shape along the width direction of the lower surface; and wherein the assembly hook portion comprises an upper hook machined with a hook shape that fits into the upper assembly groove; and a lower hook machined with a hook shape that fits into the lower assembly groove, wherein either the upper hook or the lower hook is installed to be movable in the vertical direction through a guide groove. Claim 2 In claim 1, the assembly hook portion is an ICB busbar assembly structure arranged in consideration of the number and location of installation of the busbars installed in the ICB housing. Claim 3 delete Claim 4 delete Claim 5 delete Claim 6 In claim 1, the busbar is an ICB busbar assembly structure in which, during assembly, the upper assembly groove of the busbar is coupled to an upper hook positioned in the ICB housing, and the lower assembly groove of the busbar is lowered and seated in the ICB housing while the lower hook is retracted along the guide groove, and then the lower hook is advanced and coupled to the lower assembly groove. Claim 7 An ICB busbar assembly structure manufactured according to claim 1, comprising the steps of: feeding a material into an extrusion molding machine; creating an extruded product with an upper assembly groove and a lower assembly groove along the width direction through the extrusion molding machine; and trimming the extruded product to a predetermined width length to create a plurality of Claim 8 In claim 1, the upper hook and lower hook are made of a shape-memory elastic material and are an ICB busbar assembly structure in which at least one is opened outwardly, and after the busbar is assembled, it is restored to its original shape to fix the assembled position. Claim 9 An ICB assembly comprising an ICB (Inter-Connection Board) busbar assembly structure described in any one of claims 1, 2, 6 through 8. Claim 10 An ICB assembly according to claim 9, further comprising: an electrode insertion opening that penetrates the ICB housing to expose the positive lead tab and the negative lead tab of each battery cell to the outside; and a bending guide part attached to the inner wall of the electrode insertion opening to guide the insertion path of each lead tab without interference with the internal structure. Claim 11 In claim 10, the bending guide portion forms a gentle inclined surface that covers the stepped portion formed on the inner wall of the electrode insertion opening, thereby guiding the positive lead tab and the negative lead tab so as not to catch on the stepped portion when inserted, in an ICB assembly.

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