Hinged ICB Frame for Horizontal Battery Cell Lead Connection
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Solution Overview
Problem
The existing methods for manufacturing battery modules with a horizontal stack structure are complex and difficult to implement, especially when unidirectional battery cells are stacked such that their cell leads face each other, making electrical connections challenging and time-consuming.
Innovation Solution
An interconnect board (ICB) assembly with a hinge structure that accommodates cell leads on both the top and bottom surfaces, allowing for flexible assembly of bus bars of various shapes to facilitate electrical connections between unidirectional battery cells, enabling simpler and more efficient stacking and welding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If battery cells are stacked horizontally with cell leads facing each other, then the battery module structure is compact and space-efficient, but the electrical connection process becomes complex and time-consuming
Solution Approach 1:
The ICB assembly is divided into multiple ICB frames that can be coupled together, with each frame handling specific electrical connection tasks. This segmentation allows parallel processing of connections across different frames, reducing overall connection time while maintaining the compact horizontal stacking structure.
Solution Approach 2:
The ICB assembly acts as an intermediary component between the cell leads of horizontally stacked battery cells. By providing a structured interface with multiple connection points, it simplifies the electrical connection process without requiring direct lead-to-lead welding, thus reducing connection time while maintaining compact form factor.
2Power
If multiple battery cells are connected in series and parallel to achieve higher output voltage and capacity, then the battery pack performance is improved, but the number of components and assembly complexity increases
Solution Approach 1:
The ICB frame structure is designed to handle multiple electrical connection functions simultaneously - supporting both series and parallel connections through its multiple connection points and bus bar configurations. This universal design allows the same basic structure to scale for different voltage and capacity requirements without proportionally increasing assembly complexity.
Solution Approach 2:
Multiple ICB frames are coupled together to form a unified assembly that integrates numerous electrical connection functions into a single structured unit. This merging approach consolidates what would otherwise be separate connection operations into a coordinated assembly process, reducing overall complexity despite the increased number of connected cells.
3Ease of manufacture
If a vertical stack structure is used with unit cells stood upright, then the assembly process is simplified and ICB connection is straightforward, but the cell leads must be located at one side limiting design flexibility
Solution Approach 1:
The ICB frame structure extends connections in multiple spatial dimensions rather than relying on a single vertical stacking arrangement. By providing connection points on multiple faces and levels of the frame, it accommodates cell leads from various orientations and positions, thus maintaining assembly ease while significantly improving design flexibility.
Data Source
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Figure 4(a)~4(c)
AI summary
Provided are an ICB assembly suitable for a battery module of a horizontal stack structure wherein unidirectional battery cells are stacked such that cell leads face each other, a battery module including the same and a method for manufacturing the same. The ICB assembly of the present disclosure includes an ICB frame accommodating cell leads of unidirectional battery cells having the cell leads formed on one side such that the cell leads face each other; and a bus bar electrically connected to the cell leads by being assembled to the ICB frame, wherein the cell leads are placed on the top surface and the bottom surface of the ICB frame.