A device and method for preventing wire compression in a thermal battery assembly

Abstract

The application discloses a device for preventing wire pressing during assembly of a thermal battery, comprising a flat visual wiring tool provided with a hollow area and a compacted area, the hollow area and the compacted area being divided and shaped according to the structure of the thermal battery. A wire pressing method of the device for preventing wire pressing during assembly of a thermal battery comprises the following steps: step 1, before a cover plate of a thermal battery pack is installed, a visual wiring tool is used to determine the risk of wire pressing of the thermal battery pack, and the tool is used to arrange the wires to a non-wire pressing risk state; step 2, quick drying glue is used to quickly fix the wires; and step 3, after the wires are fixed by the quick drying glue, the visual wiring tool is removed, and the cover plate of the thermal battery pack is installed. The method and the device for preventing wire pressing during assembly of a thermal battery are simple in operation method, short in production cycle, high in production efficiency, and suitable for large-batch production requirements of thermal battery covers.

Description

Technical Field

[0001] This invention belongs to the field of thermal battery technology, specifically relating to a device and method for preventing wire compression during thermal battery assembly. Background Technology

[0002] Thermal batteries are primary storage batteries that use molten salt as the electrolyte and are activated by melting it with their own heat source. They offer advantages such as short activation time, wide operating temperature range, long storage period, and maintenance-free operation, leading to their increasingly widespread use in weapon systems. However, after the thermal battery cables are welded, the wires are unconstrained, and the adhesive application and capping process is blind, lacking any protective measures. This poses a risk of wire compression after capping, and this risk cannot be detected in time, thus reducing battery reliability and urgently requiring a solution.

[0003] The current method for applying adhesive to the hot battery cover is as follows: After manually applying adhesive to the hot battery with welded cables (the adhesive is not yet cured; otherwise, due to space limitations, the cover cannot be assembled), the battery cover is directly assembled. During this operation, the wires are unrestrained, and the risk of the cover pressing on the wires cannot be identified during cover assembly.

[0004] A multi-layer separator flame-retardant safety structure for battery assembly, disclosed in CN208385500U, includes an upper cover and a lower cover. The lower cover is shell-shaped, with several longitudinal and transverse separator groups spaced apart inside. The longitudinal separator groups have nickel sheet mounting grooves for placing and installing nickel sheets. A cell cavity for placing battery cells is formed between the transverse separator groups and the inner wall of the lower cover. Protective plate mounting grooves for installing protective plates are formed between the transverse separator groups. The upper and lower covers are connected as a single unit. This invention features a recessed design for fixing the battery cells in the upper and lower covers to save space, eliminate the need for brackets, and reduce costs. The four-layer separator design of the upper and lower covers creates isolated zones for the battery cells, preventing crossfire, providing flame retardancy, explosion prevention, and ensuring safety and reliability. Nickel sheets are directly inserted into the protective plate, saving wiring harness costs and avoiding the risk of wiring harness compression, thus improving production efficiency. The combination of snap-fit ​​and adhesive dispensing results in high production efficiency and safety. However, this structure is complex and increases the pressure on tooling. Summary of the Invention

[0005] To address the aforementioned problems, the present invention aims to provide a device and method for preventing wire compression during the assembly of a thermal battery.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: a flat, visual wiring fixture is provided, wherein the visual wiring fixture is provided with a cutout area and a compaction area, the cutout area is used to identify risk points of the device, and the compaction area is used to apply quick-drying adhesive.

[0007] The location of the hollowed-out area and the compacted area is determined based on the structure of the thermal battery.

[0008] The visual wiring fixture is made of plexiglass or acrylic material.

[0009] A method for preventing wire compression during hot battery assembly, the method comprising the following steps:

[0010] Step 1: Before installing the cover plate on the thermal battery pack, use a visual wiring fixture to determine the risk of wire pressure on the thermal battery pack, and use the fixture to organize the wires to a non-risk-of-wire-pressure state.

[0011] Step 2: Quickly secure the wires with quick-drying adhesive;

[0012] Step 3: After the quick-drying adhesive cures the wires, remove the visual wiring fixture and install the thermal battery pack cover.

[0013] The quick-drying adhesive is made of type 826 high-strength and tough epoxy AB adhesive, which has an insulation value of greater than or equal to 500MΩ at 1000V and can withstand high temperatures of 150℃.

[0014] In step 1, the visual wiring fixture is placed on the thermal battery pack. The compaction area of ​​the visual wiring fixture is used to press down the wires, and the open area is used to visually determine whether there are any risks to the wires. Wires with risks are manually cleaned up.

[0015] Risks include wire crossings and extensions outside the installation area.

[0016] In step 2, arrange the wires in the cutout area and fix them in place with quick-drying adhesive. The curing time of the quick-drying adhesive is 5 to 10 minutes.

[0017] The disassembled visual tooling can be reused to perform wiring production for the same type of battery.

[0018] Compared with existing technologies, this invention has the following advantages: it adopts a visual tooling combined with an accelerated adhesive preparation method for hot battery wire routing, which can significantly reduce the risk of wire pressing during hot battery adhesive dispensing and capping, improve the reliability of hot batteries, and the method has a short operation cycle, making it suitable for the mass production needs of hot batteries; at the same time, the visual tooling has a simple structure, can be recycled multiple times, and saves costs. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the specific embodiments of the present invention, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1This is a schematic diagram of the thermal battery wiring structure in this invention;

[0021] Figure 2 This is a schematic diagram of the visual tooling structure in this invention;

[0022] Figure 3 for Figure 2 A visual schematic diagram of tooling assembly to prevent creasing;

[0023] In the diagram, 1-Quick-drying adhesive; 2-Visual tooling; 3-Thermal battery pack; 21-Hollowed-out area; 22-Compacted area. Detailed Implementation

[0024] The present invention will be further described below with reference to the accompanying drawings and specific embodiments. However, it should not be construed that the scope of the subject matter of the present invention is limited to the following embodiments. All modifications, substitutions and alterations made based on ordinary technical knowledge and conventional means in the art without departing from the above-described technical concept of the present invention are included within the scope of the present invention.

[0025] Reference Figures 1-3 The thermal battery assembly anti-crushing device includes a visual fixture 2 with different crrushing shapes. The visual fixture 2 is used to prevent crrushing during the assembly of thermal batteries of different specifications and models.

[0026] Visualized wiring fixture 2 is used for fixing the wires of the thermal battery pack 3 and assessing the risk of wire overlap; quick-drying adhesive 1 is used for rapid wire fixing. When assembling and installing the cover plate of the thermal battery pack 3, the visualized wiring fixture 2 is first used to assess the risk of wire overlap, such as wires overlapping or extending beyond the installation area. Simultaneously, the wires are tidied up to a non-risk-prone state. Then, quick-drying adhesive 1 is used for rapid wire fixing. The curing time of quick-drying adhesive 1 is 5-10 minutes. If the curing time is less than 5 minutes, the curing is insufficient, affecting the fixing effect; if the time exceeds 10 minutes, it is time-consuming and reduces work efficiency. After the quick-drying adhesive 1 has cured, the visualized wiring fixture 2 can be removed, and wiring production for another battery pack can begin.

[0027] Visualized wiring fixture 2 is designed according to the structure of different thermal batteries, and is made of plexiglass or acrylic material. Quick-drying adhesive 1 is made of 826 type high-strength and tough epoxy AB glue. This glue has an insulation value of greater than or equal to 500MΩ at 1000V, can withstand high temperature of 150℃, and has a curing time of 5min to 10min. All its properties meet the performance requirements of thermal batteries.

[0028] Example: Figure 1The diagram shows the wiring structure of this thermal battery. With only 3mm of space for wiring, it requires routing 16 0.35mm² wires, 12 0.75mm² wires, and 4 1mm² wires. Without anti-crushing design, the risk of wire compression is extremely high. The wire compression method includes the following steps:

[0029] Step 1: Before installing the cover plate on the thermal battery pack, place the thermal battery pack 3 with welded cables, the visual wiring fixture 2, and the quick-drying adhesive 1 on the workbench; place the visual wiring fixture 2 on the thermal battery pack 3, press the wires with the compaction area 22 of the visual wiring fixture 2, and use the cutout area 21 to visually determine whether there is any risk in the wires, and manually tidy up any wires with risks.

[0030] Step 2: Anti-crushing operation, use quick-drying adhesive 1 to fix the wires, and the curing time is 5 min to 10 min;

[0031] Step 3: After the quick-drying adhesive 1 dries, remove the visual wiring fixture 2. After the above actions are completed, apply hot battery adhesive to the top cover. The removed visual wiring fixture 2 can be used for wiring production of another battery pack.

[0032] The foregoing has provided a detailed description of the device and method for preventing wire compression during hot battery assembly according to the present invention. Specific examples have been used to illustrate the structure and working principle of the invention. The descriptions of the embodiments above are merely for the purpose of helping to understand the method and core ideas of the present invention. It should be noted that those skilled in the art can make various improvements and modifications to the present invention without departing from its principles, and these improvements and modifications also fall within the scope of protection of the claims of the present invention.

Claims

1. A device for preventing wire compression during the assembly of a thermal battery, characterized in that: Used to assess the risk of wire pressing before assembling and installing the cover plate of the hot battery pack; After the wires are fixed, they are removed for use in the wiring production of the next thermal battery pack. The device includes a flat, visual wiring fixture for fitting onto a thermal battery pack. The fixture has a cutout area and a compaction area. The compaction area is used to press down the wires of the thermal battery pack, and the cutout area is used to identify risk points of the thermal battery pack and apply quick-drying adhesive to the wires inside. The risk points include wire crossings and wires extending outside the installation area.

2. The battery assembly anti-crushing device according to claim 1, characterized in that: The location of the hollowed-out area and the compacted area is determined based on the structure of the thermal battery.

3. The battery assembly anti-crushing device according to claim 1, characterized in that: The visual wiring fixture is made of plexiglass or acrylic material.

4. A method for preventing wire pressing during the assembly of a thermal battery using the anti-wire pressing device described in claim 1, 2, or 3, characterized in that: The crimping method includes the following steps: Step 1: Before installing the cover plate on the thermal battery pack, use a visual wiring fixture to determine the risk of wire pressure on the thermal battery pack, and use the visual wiring fixture to organize the wires to a non-risk-of-wire-pressure state. Step 2: Quickly fix the wires with quick-drying adhesive, and the curing time is 5 min to 10 min; Step 3: After the quick-drying adhesive cures the wires, remove the visual wiring fixture and install the thermal battery pack cover.

5. The method for preventing wire pressing during hot battery assembly according to claim 4, characterized in that: The quick-drying adhesive is made of type 826 high-strength and tough epoxy AB adhesive, which has an insulation value of greater than or equal to 500MΩ at 1000V and can withstand high temperatures of 150℃.

6. The method for preventing wire compression during hot battery assembly according to claim 4, characterized in that: In step 1, the visual wiring fixture is placed on the thermal battery pack. The compaction area of ​​the visual wiring fixture is used to press down the wires, and the open area is used to visually determine whether there are any risks to the wires. Wires with risks are manually cleaned up.

7. The method for preventing wire compression during hot battery assembly according to claim 4, characterized in that: In step 2, arrange the wires in the cutout area and fix them in place with quick-drying adhesive.

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