INTERCONNECTION ASSEMBLIES AND METHODS FOR FORMING THE INTERCONNECTION ASSEMBLIES IN A BATTERY MODULE

• US 20130052511A1
• Filed: 08/31/2011
• Published: 02/28/2013
• Est. Priority Date: 08/31/2011
• Status: Active Grant

• Current Assignee: LG Energy Solution Limited (LG Corporation)
• Original Assignee: LG Chem Limited (LG Corporation)
• Inventors: Khakhalev, Alex
• Granted Patent: US 8,871,376 B2
• Time in Patent Office: Days
• US Class Current: 429/158
• CPC Class Codes: B23K 1/0016 Brazing of electronic components
• CPC Class Codes: B23K 20/10 making use of vibrations, e.g. ultrasonic welding
• CPC Class Codes: B23K 2101/38 Conductors
• CPC Class Codes: H01M 50/503 characterised by the shape of the interconnectors
• CPC Class Codes: H01M 50/516 by welding, soldering or brazing
• CPC Class Codes: H01M 50/522 Inorganic material
• CPC Class Codes: H01M 50/528 Fixed electrical connections, i.e. not intended for disconnection
• CPC Class Codes: H01M 50/529 Intercell connections through partitions, e.g. in a battery casing
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

Interconnection assemblies and methods are provided. An interconnection assembly includes a first cell tab constructed of a first metal, and a second cell tab disposed against the first cell tab. The second cell tab is constructed of a second metal having a hardness greater than the first metal. The assembly further includes an interconnect member disposed against the second cell tab. The assembly further includes a weld assisting layer disposed against the first cell tab such that the first and second cell tabs are disposed between the weld assisting layer and the interconnect member.

Claims

1. An interconnection assembly, comprising:

a first cell tab of a first battery cell, the first cell tab being constructed of a first metal;

a second cell tab of a second battery cell, the second cell tab disposed against the first cell tab, the second cell tab being constructed of a second metal, the second metal having a hardness greater than a hardness of the first metal;

an interconnect member disposed against the second cell tab; and

a weld assisting layer disposed against the first cell tab such that the first and second cell tabs are disposed between the weld assisting layer and the interconnect member, such that when a welding joint is formed in the first and second cell tabs, the interconnect member, and the weld assisting layer, the weld assisting layer reduces deformation of the first cell tab.

2. The interconnection assembly of claim 1, wherein the first metal is aluminum.

3. The interconnection assembly of claim 2, wherein the second metal is copper.

4. The interconnection assembly of claim 3, wherein the weld assisting layer has a flat wall portion and an arcuate-shaped portion extending from the flat body portion.

5. The interconnection assembly of claim 1, the weld assisting layer is constructed of either the second metal or a third metal.

6. The interconnection assembly of claim 1, wherein the interconnect member is constructed of either the second metal or a third metal.

7. A method of forming an interconnection assembly in a battery module, comprising:

providing a first cell tab of a first battery cell, a second cell tab of a second battery cell, an interconnect member, and a weld assisting layer, the first cell tab being constructed of a first metal, the second cell tab being constructed of a second metal, the second metal having a hardness greater than a hardness of the first metal;

disposing the second cell tab against the first cell tab;

disposing the interconnect member against the second cell tab;

disposing the weld assisting layer against the first cell tab such that the first and second cell tabs are disposed between the weld assisting layer and the interconnect member; and

ultrasonically welding together the first and second cell tabs, the interconnect member, and the weld assisting layer utilizing an ultrasonic welding machine.

8. The method of claim 7, wherein the first metal is aluminum.

9. The method of claim 8, wherein the second metal is copper.

10. The method of claim 7, wherein the weld assisting layer is constructed of either the second metal or a third metal.

11. The method of claim 7, wherein the interconnect member is constructed of either the second metal or a third metal.

12. An interconnection assembly, comprising:

a first cell tab of a first battery cell, the first cell tab being constructed of a first metal;

a second cell tab of a second battery cell disposed against the first cell tab, the second cell tab being constructed of a second metal, the second metal having a hardness greater than a hardness of the first metal; and

an interconnect member having a U-shaped portion and an extension portion coupled to an end of the U-shaped portion, at least a portion of the first cell tab and at least a portion of the second cell tab being disposed within an open region defined by the U-shaped portion and contacting the U-shaped portion, such that when a welding joint is formed in the first and second cell tabs, the interconnect member, and the U-shaped portion, the U-shaped portion reduces deformation of the first cell tab.

13. The interconnection assembly of claim 12, wherein the first metal is aluminum.

14. The interconnection assembly of claim 13, wherein the second metal is copper.

15. The interconnection assembly of claim 12, wherein the interconnect member is constructed of either the second metal or a third metal.

16. A method of forming an interconnection assembly in a battery module, comprising:

providing a first cell tab of a first battery cell, a second cell tab of a second battery cell, an interconnect member having a U-shaped portion and an extension portion coupled to a first end of the U-shaped portion, the first cell tab being constructed of a first metal, the second cell tab being constructed of a second metal, the second metal having a hardness greater than a hardness of the first metal;

disposing at least a first portion of the first cell tab and at least a second portion of the second cell tab within an open region defined by the U-shaped portion of the interconnect member such that the first and second portions contact the U-shaped portion; and

ultrasonically welding together the first and second cell tabs and the U-shaped portion of the interconnect member, utilizing an ultrasonic welding machine.

17. The method of claim 16, wherein the first metal is aluminum.

18. The method of claim 17, wherein the second metal is copper.

19. The method of claim 16, wherein the interconnect member is constructed of either the second metal or a third metal.