Hinged ICB Assembly for Horizontal Battery Module Welding
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Solution Overview
Problem
The existing methods for fabricating battery modules with a horizontal stack structure of unidirectional battery cells facing each other are complex, requiring sequential stacking and welding, making them difficult to assemble and expand.
Innovation Solution
An interconnect board (ICB) assembly with a hinge structure that allows for the horizontal stacking and simultaneous welding of unidirectional battery cells, enabling easy assembly and expansion by connecting additional battery cells in series through a simple process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If sequential stacking and welding methods are used for horizontal stack structure battery modules, then the fabrication process can be completed, but the assembly becomes complex and difficult to expand
Solution Approach 1:
The battery module is divided into multiple standardized battery packs, each containing a fixed number of battery cells (e.g., 2 cells per pack). These modular units can be independently manufactured and then easily assembled by connecting multiple packs together, significantly simplifying the overall fabrication process and enabling straightforward expansion by adding or removing packs.
Solution Approach 2:
Battery cells are pre-assembled into complete battery packs with all necessary components (battery cells, connection terminals, housing) before final module assembly. This preliminary preparation of standardized units eliminates the need for complex sequential stacking and welding operations during final assembly, as packs can be quickly connected through simplified interfaces.
2Adaptability or versatility
If conventional ICB assembly is used for vertical stack structure, then electrical connection can be achieved, but it cannot be used for horizontal stack structure with unidirectional battery cells
Solution Approach 1:
The interconnect board assembly is designed with a universal structure that can accommodate both vertical and horizontal battery cell arrangements. The ICB features standardized connection interfaces and flexible terminal configurations that adapt to different battery pack orientations and connection patterns, ensuring reliable electrical connections across multiple structural configurations without requiring design changes.
3Volume of moving object
If battery cells are stacked horizontally facing each other, then space utilization improves, but the fabrication process becomes more complex
Solution Approach 1:
By segmenting the battery module into standardized packs with horizontal cell arrangements, the design achieves efficient space utilization within each pack while maintaining fabrication simplicity through modular assembly. The segmentation allows optimal packing density in the horizontal orientation without requiring complex fabrication processes, as each module is built from pre-assembled standard units.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Simplifies the battery module fabrication process by allowing all-at-once welding and stacking, facilitating mass production and easy expansion of the battery module with a straightforward electrical connection method.
Implementation Method 1
the bent parts of the cell leads 12 are welded by a laser LB outputted from a laser generator LG
Data Source
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AI summary
Provided are an interconnect board (ICB) assembly suitable for a battery module of horizontal stack structure including unidirectional battery cells stacked with cell leads facing each other, a battery module comprising the same and a method for fabricating the battery module. The ICB assembly according to the present disclosure includes an ICB frame in which cell leads of unidirectional battery cells are received such that the unidirectional battery cells having the cell leads at one end are placed facing each other with the cell leads facing each other, and busbars formed in the ICB frame and electrically connected to the cell leads, wherein the ICB assembly is connected to another ICB frame with a hinge structure in a lengthwise direction of the ICB frame.