Integrated ICB with Cell Tab Comb Features
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Solution Overview
Problem
The assembly of traction battery packs in electric-drive vehicles is complex and prone to errors, with existing interconnect boards requiring multiple steps and risking cell misalignment or shorting during installation, which complicates manufacturing and increases the risk of incorrect connections.
Innovation Solution
An integrated electrical interconnect board (ICB) with a C-shaped module jacket and orthogonal endwalls featuring vertical slots for vertical mounting and combing of battery cells, simplifying installation and reducing the risk of errors by eliminating unnecessary assembly steps and incorporating tooling features for easier assembly and reduced manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional interconnect boards are used with multiple assembly steps, then electrical connections can be established, but the assembly process becomes complex and prone to errors including cell misalignment and shorting
Solution Approach 1:
The patent combines the interconnect board with the module jacket into a single integrated assembly. The C-shaped module jacket incorporates endwalls with vertically elongated slots that directly receive cell tabs, eliminating the need for separate interconnect boards and reducing assembly steps while maintaining reliable electrical connections
Solution Approach 2:
The vertically elongated slots are pre-formed in the endwalls during jacket manufacturing, preparing the structure in advance to guide cell tabs into correct alignment. This preliminary preparation prevents misalignment and shorting during assembly without requiring complex alignment procedures
2Reliability
If multiple assembly steps are used for ICB installation, then electrical connections can be made, but manufacturing time and production cost increase
Solution Approach 1:
By merging the ICB functionality into the module jacket structure, the patent enables single-step installation where the jacket is mounted and electrical connections are established simultaneously. This eliminates multiple sequential assembly steps, directly improving production speed while maintaining connection reliability
Solution Approach 2:
The module jacket serves multiple functions: structural protection, electrical insulation, and electrical connection establishment through its integrated endwalls with slots. This multi-functionality eliminates the need for separate dedicated ICB components and assembly steps, enhancing both productivity and reliability
3Reliability
If traditional ICB designs are used, then electrical connections can be established, but manufacturing tooling requirements increase and costs rise
Solution Approach 1:
The integration of ICB features into the module jacket reduces the number of discrete components that require separate manufacturing and assembly tooling. The C-shaped jacket with built-in endwalls and slots can be manufactured as a single molded piece, simplifying tooling requirements and reducing manufacturing complexity while ensuring reliable connections
Data Source
AI summary
Presented are integrated electrical interconnect board (ICB) assemblies for battery modules, rechargeable traction battery packs equipped with such ICB assemblies, and methods for making/using such ICB assemblies. A battery module for storing and supplying electrical energy includes multiple battery cells that are stacked in side-by-side facing relation with one another and each has a battery cell casing with an electrical terminal projecting therefrom. An electrically insulating module housing has a housing base that supports thereon the stacked battery cells. An integrated ICB assembly, which is attached to the module housing, includes a central cover in spaced facing relation to the housing base, endwalls projecting from the central cover, and multiple busbar connectors attached to the endwalls and electrically connected to the battery cells' electrical terminals. Each endwall has multiple elongated slots that extend from a distal edge of the endwall and slidably receives therethrough one of the electrical terminals.