ICB Assembly Bridge Plate Layout for Higher-Density Battery Modules
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Solution Overview
Problem
Conventional battery modules face challenges in maximizing energy density due to the top frame reducing the width of the cell stack and complicating assembly dimensional tolerances, leading to reduced yield and assembly difficulties.
Innovation Solution
The proposed battery module incorporates an ICB assembly with bridge plates to maintain a constant gap between bus bar frames, allowing for a minimized component count and improved assembly efficiency, while replacing the top frame with bridge plates to increase energy density and facilitate easier assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a top frame is added to protect the upper portion of the cell stack and FPC, then the protective function is improved, but the width of the cell stack is reduced and energy density decreases
Solution Approach 1:
The patent removes the top frame component from the conventional ICB assembly structure. Instead of adding protection from above, the design relies on the bus bar frames and FPC routing to provide necessary structural support and protection, eliminating the space-consuming top frame that reduced cell stack width and energy density.
Solution Approach 2:
The patent changes the protective structure from a vertical dimension (top frame covering the upper portion) to a horizontal integration approach where the bus bar frames and FPC are integrated within the same plane as the cell stack, maximizing width utilization while providing protection through alternative structural arrangements.
2Reliability
If a top frame is added to protect the upper portion of the cell stack and FPC, then the protective function is improved, but assembly dimensional tolerances become difficult to meet and yield deteriorates
Solution Approach 1:
By removing the top frame, the patent eliminates the source of assembly tolerance problems. The conventional design required precise positioning of the top frame relative to the cell stack and FPC, but the new design integrates protection functions into the bus bar frames and FPC routing, which have more forgiving tolerance requirements.
Solution Approach 2:
The patent merges the protective function with the existing bus bar frames and FPC structure rather than adding a separate top frame component. This integration reduces the number of interfaces and assembly steps, thereby simplifying dimensional tolerance control and improving manufacturing yield.
3Reliability
If a top frame is added to protect the upper portion of the cell stack and FPC, then the protective function is improved, but the component count increases and assembly complexity increases
Solution Approach 1:
The patent extracts and removes the top frame component from the ICB assembly, reducing the total component count. The protective function is redistributed to existing components (bus bar frames and FPC), eliminating the need for additional assembly steps and reducing overall assembly complexity.
Solution Approach 2:
The patent combines multiple functions (structural support, electrical connection, and protection) into the existing bus bar frames and FPC rather than adding a separate top frame. This functional integration reduces component count and simplifies the assembly process by eliminating additional assembly operations.
Data Source
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AI summary
Disclosed is a battery module. The battery module includes a cell stack having a plurality of battery cells stacked in one direction, and an ICB assembly electrically connected to the plurality of battery cells to sense voltage information. The ICB assembly includes a front bus bar frame assembled to a front side of the cell stack and a rear bus bar frame assembled to a rear side of the cell stack, the front bus bar frame and the rear bus bar frame respectively having a plurality of bus bars that are in contact with electrode leads of the battery cells; a sensing member assembled such that one side thereof is fixed to the front bus bar frame and the other side thereof is fixed to the rear bus bar frame; and at least one bridge plate connected to the front bus bar frame and the rear bus bar frame to keep a gap between the front bus bar frame and the rear bus bar frame constant.