ICB Assembly for Horizontal Battery Cell Lead Connection
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Solution Overview
Problem
The existing methods for fabricating battery modules with a horizontal stack structure are complex and difficult to assemble, particularly due to the need for sequential stacking and welding of unidirectional battery cells with facing cell leads, which complicates electrical connections and expansion.
Innovation Solution
An interconnect board (ICB) assembly with a customizable frame and busbars of various shapes is used to facilitate the horizontal stacking and electrical connection of unidirectional battery cells, allowing for simultaneous welding and stacking, and easy expansion by adding more units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sequential stacking and welding of unidirectional battery cells is used to form horizontal stack structure, then electrical connections can be established, but the fabrication process becomes complex and difficult to assemble
Solution Approach 1:
The battery module is divided into multiple unit cells, each comprising a battery cell and an ICB assembly. This segmentation allows each unit to be independently assembled and then stacked horizontally, simplifying the overall fabrication process while maintaining reliable electrical connections through the modular ICB assemblies.
Solution Approach 2:
The ICB assembly is pre-assembled with busbars positioned to receive cell leads before the battery cells are stacked. This preliminary arrangement of electrical connection components eliminates the need for complex sequential welding operations during final assembly, as the busbars are already in their correct positions to receive the cell leads.
2Shape
If horizontal stack structure with facing cell leads is used, then battery module can be formed, but assembly becomes difficult and expansion is complicated
Solution Approach 1:
The ICB assembly serves multiple functions: it provides mechanical support for the battery cells, establishes electrical connections through busbars, and facilitates horizontal stacking. The standardized ICB design with receptacles for cell leads and mounting structures enables universal application across different battery module configurations, simplifying both assembly and expansion.
Solution Approach 2:
The cell leads are inserted into receptacles on the ICB assembly, with the busbars nested within the ICB structure. This nested arrangement allows the cell leads to be received and electrically connected in a compact configuration, enabling easy horizontal stacking of battery cells while maintaining organized electrical connections.
3Reliability
If multiple battery cells are connected with facing cell leads, then electrical connections can be established, but the connection process becomes complex
Solution Approach 1:
The busbars serve as intermediary components that facilitate electrical connections between multiple battery cells. Instead of directly connecting cell leads from different cells, the busbars mediate the connection by receiving leads from multiple cells and establishing the electrical pathway, thereby simplifying the connection process while ensuring reliable electrical connectivity.
Solution Approach 2:
The ICB assembly uses identical busbar designs and receptacle configurations across multiple units. This copying of the standardized connection structure allows for repetitive, simplified manufacturing processes, as each ICB assembly can be produced using the same template and assembly procedures, reducing manufacturing complexity.
Data Source
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 configured to receive leads of unidirectional battery cells 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 assembled in the ICB frame, size and configured to be electrically connected to the cell leads.