ICB Assembly for Horizontal Battery Cell Stacking and Welding
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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 plate-type 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 changing busbar configurations.
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 fabrication process becomes complex and difficult to assemble
Solution Approach 1:
The battery module is divided into multiple unit cells, each with a standardized structure containing battery cells stacked horizontally. This segmentation allows for modular assembly and simplifies the overall fabrication process while maintaining compact volume.
Solution Approach 2:
An interconnect board assembly is introduced as an intermediary component to facilitate electrical connections between cell leads. The interconnect board with busbars provides a standardized interface that simplifies the assembly process and reduces fabrication complexity.
2Reliability
If sequential stacking and welding of battery cells is performed, then electrical connections are established, but the assembly process is time-consuming and complex
Solution Approach 1:
The interconnect board assembly is prepared in advance with busbars positioned and configured before battery cell assembly. This preliminary preparation allows for faster and more reliable electrical connections during the final assembly stage, reducing overall assembly time.
Solution Approach 2:
Multiple battery cells are stacked and connected simultaneously in a single assembly operation rather than sequentially. The interconnect board enables multiple electrical connections to be established at once, significantly reducing assembly time while maintaining connection reliability.
3Adaptability or versatility
If multiple busbar configurations are used for different electrical connections, then various electrical relationships between battery cells can be achieved, but the device complexity increases
Solution Approach 1:
The interconnect board assembly is designed as a universal component that can accommodate multiple busbar configurations. The same basic interconnect board structure can be adapted for different electrical connections (series, parallel, or combinations) by simply changing the busbar arrangement, providing versatility without increasing overall device complexity.
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
This approach simplifies the fabrication process, enables easy assembly, and allows for the simplest connection among multiple possible electrical relationships between battery cells, making it suitable for mass production and easy expansion of battery modules.
Implementation Method 1
welding the busbars and the cell leads together on a top side
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 assembled in the ICB frame and electrically connected to the cell leads.