Battery Module ICB Cover Layering for Welding Pitch Control
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Solution Overview
Problem
The challenge is to maintain a predetermined welding pitch between electrode leads in battery cells with small cell thickness, which leads to interference and poor welding quality.
Innovation Solution
The solution involves using interconnect board (ICB) covers arranged in different layers, with first and second ICB covers disposed at specific locations, and electrode lead connections bent to different angles or shapes to prevent contact and ensure a consistent welding pitch.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cell thickness is reduced to improve energy density, then productivity and energy density are improved, but welding pitch cannot be maintained and electrode leads interfere with each other
Solution Approach 1:
The patent introduces a multi-layered ICB cover structure where electrode leads are connected in different layers (first ICB cover and second ICB cover at different positions). This spatial arrangement in multiple dimensions prevents interference between electrode leads while maintaining the required welding pitch, even when cell thickness is reduced to improve energy density.
2Productivity
If cell thickness is reduced, then productivity is improved, but electrode leads interfere at bending portions making welding difficult
Solution Approach 1:
By arranging ICB covers at different positions (different layers), the patent creates sufficient spatial separation between electrode leads. This allows electrode leads to be bent and welded without interference, even in thin cells, thereby maintaining ease of manufacture and welding quality while enabling cell thickness reduction.
Solution Approach 2:
The patent divides the connection structure into multiple segments (first ICB cover and second ICB cover at different positions). This segmentation allows each electrode lead to be independently managed and welded without interference from adjacent leads, improving ease of manufacture while maintaining reduced cell thickness.
3Manufacturing precision
If multiple ICB covers are arranged in different layers, then welding pitch is maintained and welding quality is improved, but device complexity increases
Solution Approach 1:
The patent uses a multi-layered ICB cover arrangement where the first and second ICB covers are positioned at different locations. This spatial distribution in multiple dimensions maintains welding pitch and quality while organizing the complexity in a structured manner that is manageable during assembly.
Data Source
AI summary
A battery module includes: a battery cell stack including a plurality of battery cells respectively having electrode leads, the plurality of battery cells being stacked on one another; and an interconnect board (ICB) cover to which an electrode lead connection that is bent is coupled, the electrode lead connection comprising an electrode lead of any one of the plurality of battery cells and an electrode lead of another battery cell adjacent to the any one battery cell connected to each other, wherein a plurality of the ICB covers is provided, and the plurality of ICB covers are arranged in different layers.