Battery decoupling method

Abstract

A method of decoupling a first component 102 of a battery assembly 100 from a second component 104, wherein the inner surfaces 112, 116 of the components are joined using an adhesive 106 and wherein t

Description

TECHNICAL FIELD The present disclosure relates to a battery decoupling method. Aspects of the invention relate to a method of decoupling a first component of a battery assembly from a second component of the battery assembly. BACKGROUND It is known to provide batteries, for example for electric vehicles, which include a number of cells which are arranged in a stack and / or a module and individually housed, adhered together and provided within a thermal insulator such as expanding foam. Such an arrangement is referred to as a battery pack. The pack arrangement protects the cells from external shocks, heat or vibration. However, in the event that one of the cells within the pack becomes damaged or otherwise reaches the end of its useful life, it is a laborious task to remove the individual cell and so it often becomes necessary to replace the entire battery. It is desirable to recycle the valuable components of a battery at the end of its life. Present methods of recycling are labour and energy intensive. An example of one method involves an operative or team breaking down the battery with tools. A less labour-intensive method involves destroying the battery in a shredder, melting or burning off the less valuable components, such as the housing, and recovering the valuable components, e.g. of the cells and connectors. A disadvantage of this approach is that impurities may be retained within the recovered components. It is an aim of the present invention to address one or more of the disadvantages associated with the prior art. SUMMARY OF THE INVENTION Aspects and embodiments of the invention provide a method of decoupling a first component of a battery assembly from a second component of the battery assembly as claimed in the appended claims. According to an aspect of the present invention there is provided a method of decoupling a first component of a battery assembly from a second component of the battery assembly, wherein the first component is coupled to the second component using an adhesive. The method includes increasing a temperature of one of the first component and the second component and using the heated one of the first component and the second component to increase the temperature of the adhesive. The first component and the second component of the battery assembly are in contact with the adhesive and so by heating one of the first component and the second component and using the heated one of the first component and the second component, it is possible to increase the temperature of the adhesive without unnecessarily heating other elements of the battery assembly. Localised heating is also more energy efficient. According to another aspect of the invention, there is provided a method of decoupling a first component of a battery assembly from a second component of the battery assembly. An inner surface of the first component is coupled to an inner surface of the second component using an adhesive. The method includes applying a heating element to an outer surface of one of the first component and the second component; increasing a temperature of the one of the first component and the second component using the heating element; and increasing a temperature of the adhesive between the first component and the second component using the one of the first component and the second component. The adhesive may be a structural adhesive that provides shear and tensile strength to the battery assembly. Structural adhesives advantageously protecting the battery assembly against external forces such as impacts, vibrations and loads, without unduly increasing the weight of the battery assembly. The adhesive, for example the structural adhesive, may include an acrylic-based adhesive, an epoxy-based adhesive, a urethane-based adhesive or a silicone-based adhesive. These adhesives provide one or more of the following benefits: ease of application, ability to bond a range of materials, quick setting, strength, thermal performance and / or durability. The adhesive, for example the structural adhesive, may be a wet-applied adhesive, for example a liquid, paste or gel adhesive. In some embodiments, the adhesive, for example the structural adhesive, may be a solid adhesive, for example a tape or a pad. By applying heat locally, to a component of the battery assembly, it is possible to efficiently increase the temperature of the adhesive in order to loosen the bonds within the adhesive, thereby loosening the adhesive bond between the first component and the second component. In an embodiment, the invention includes decoupling the first component from the second component. Advantageously, the invention enables the heated component to be decoupled from other components) of the battery assembly without damaging components of the battery assembly. The invention thus enables one or more components of the battery assembly to be removed, for example to be repaired, replaced or recycled. The invention may include increasing the temperature of the one of the first component and the second component by electrically heating the one of the first component and the second component. The heating element may, for example, be an electrical heating element. Advantageously, using an electrical heating element makes it possible to decouple components of the battery assembly during heating, which is not possible using other heating elements, for example heating elements including fluids. Additionally, or alternatively, the invention may include increasing the temperature of the one of the first component and the second component by conduction. In other words, the heating element may be placed in physical contact with one of the first component and the second component such that heat from the heating element is transferred to the one of the first component and the second component by conduction. Using a heating element that increases the temperature of the one of the first component and the second component by conduction is beneficial as it allows greater control of the rate at which the temperature of the one of the first component and the second component is increased, as well as the temperature to which the one of the first component and the second component is heated. The heating element may be a portable electrical heating element, for example a heater mat. The step of applying the heating element to the outer surface of the one of the first component and the second component may include applying the heater mat to a surface of the one of the first component and the second component. The surface may for example be an outer surface of the one of the first component and the second component. The outer surface may be opposite the inner surface of the one of the first component and the second component such that the heater mat is applied to a surface of the one of the first component and the second component that is in physical contact with the surface of the one of the first component and the second component that is in physical contact with the adhesive. The use of a heater mat enables the outer surface of the one of the first component and the second component to be heated by conduction, which as discussed above is more controllable and efficient than using methods that rely on convection of heat (e.g. heat gun). The use of a heater mat is also more convenient as it can be put in position and controlled remotely, and it doesn't require complex and / or expensive equipment. In an embodiment, the heating element is sized such that a length and a width of the heating element is at least the same as (or greater than) a length and a width of the one of the first component and the second component to which, or on which, the heating element is applied. The heating element, for example the heater mat, is sized to cover the outer surface of the component, which beneficially improves the efficiency with which the one of the first component and the second component is heated. As the adhesive will be in contact with the substantially all of the inner surface of the component, using a heating element having a surface area that corresponds to the surface area of the one of the first component and the second component beneficially ensures that the temperature of the surface of the one of the first component and the second component increases evenly. The heating element, for example the heater mat, may be used to increase the temperature of the one of the first component and the second component to at least 50°C, for example to at least 55°C, for example to at least 60°C. The heating element, for example the heater mat, may be used to increase the temperature of the one of the first component and the second component to less than or equal to 130°C, for example less than or equal to 125°C, for example less than or equal to 120°C, for example less than or equal to 115°C. The heating element, for example the heater mat, may be used to increase the temperature of the one of the first component and the second component to between 50°C and 130°C, for example to between 50°C and 125°C, for example to between 50°C and 120°C, for example to between 50°C and 115°C. The heating element, for example the heater mat, may be used to increase the temperature of the one of the first component and the second component to between 55°C and 130°C, for example to between 55°C and 125°C, for example to between 55°C and 118°C, for example to between 55°C and 115°C. The heating element, for example the heater mat, may be used to increase the temperature of the one of the first component and the second component to between 60°C and 130°C, for example to between 60°C and 125°C, for example to between 60°C and 118°C, for example to between 60°C and 115°C. The heating element, for example the heater mat, may be used to increase the temperature of the one of the first component and the second component to between approximately 60°C and approximately 130°C. The heating element, for example the heater mat, can be controlled to accurately increase the temperature of the one of the first component and the second component to an appropriate temperature range such that heat is transferred to the adhesive and increases the temperature of the adhesive, thereby causing the adhesive to be weakened. The heater mat may comprise a flexible material, for example silicone. Advantageously, the flexible heater mat conforms to the surface of the one of the first component and the second component to efficiently increase the temperature of the one of the first component and the second component. The heater mat may include an adhesive backing. The adhesive backing beneficially enables the heater mat to be releasably secured in position on the one of the first component and the second component. The heating element, for example the heater mat may be operated at a power of at least 50 Watts, for example at least 150 Watts, for example at least 250 Watts. The heating element, for example the heater mat, may be operated at a power of less than or equal to 1000 Watts, for example less than or equal to 400 Watts, for example less than or equal to 300 Watts. The heating element, for example the heater mat, may be operated at a power between 50 Watts and 1000 Watts, for example between 50 Watts and 400 Watts, for example between 50 Watts and 300 Watts. The heating element, for example the heater mat, may be operated at a power between 150 Watts and 1000 Watts, for example between 150 Watts and 400 Watts, for example between 150 Watts and 300 Watts. The heating element, for example the heater mat, may be operated at a power between 250 Watts and 1000 Watts, for example between 250 Watts and 400 Watts, for example between 520 Watts and 300 Watts. The heating element, for example the heater mat may be operated at a voltage of at least 12 Volts, for example at least 24 Volts. The heating element, for example the heater mat, may be operated at a voltage of less than or equal to 240 Volts, for example less than or equal to 115 Volts. The heating element, for example the heater mat, may be operated at a voltage between 12 Volts and 240 Volts, for example between 12 Volts and 115 Volts. The heating element, for example the heater mat, may be operated at a voltage between 24 Volts and 240 Volts, for example between 24 Volts and 115 Volts. The heating element, for example the heater mat, is operated at a suitable power / voltage to increase the temperature of the one of the first component and the second component to a temperature, thereby enabling the adhesive between the first component and the second component to be heated to a temperature at which it is weakened, thereby allowing the first component and the second component to be decoupled efficiently. Heat from the one of the first component and the second component to which the heating element is applied transfers through the one of the first component and the second component by conduction. In this way, the heated one of the first component and the second component may increase the temperature of the adhesive to at least 25°C, for example to at least 30°C, for example to at least 35°C. The heated one of the first component and the second component may increase the temperature of the adhesive to less than or equal to 95°C, for example to less than or equal to 90°C, for example to less than or equal to 85°C, for example to less than or equal to 80°C. The heated one of the first component and the second component may increase the temperature of the adhesive to between 25°C and 95°C, for example to between 25°C and 90°C, for example to between 25°C and 85°C, for example to between 25°C and 80°C. The heated one of the first component and the second component may increase the temperature of the adhesive to between 30°C and 95°C, for example to between 30°C and 90°C, for example to between 30°C and 85°C, for example to between 30°C and 80°C. The heated one of the first component and the second component may increase the temperature of the adhesive to between 35°C and 95°C, for example to between 35°C and 90°C, for example to between 35°C and 85°C, for example to between 35°C and 80°C. The heated one of the first component and the second component may increase the temperature of the adhesive to between approximately 30°C and approximately 90°C. Advantageously, the heated one of the first component and the second component can increase the temperature of the adhesive to a temperature within a range which is appropriate to cause the adhesive to be weakened, thereby allowing the battery components to be decoupled and disassembled. In an embodiment of the invention, the step of increasing the temperature of the one of the first component and the second component using the heating element may have a duration. The duration may, for example, correspond to the length of time for which the heating element, for example the heater mat, is applied to the one of the first component and the second component. The duration may be at least 20 seconds, for example at least 30 seconds, for example at least 60 seconds, for example at least 300 seconds, for example at least 900 seconds. The duration may be at less than or equal to 3600 seconds, for example less than or equal to 2700 seconds, for example less than or equal to 1800 seconds. The duration may be between 20 seconds and 3600 seconds, for example between 20 seconds and 2700 seconds, for example between 20 seconds and 1800 seconds. The duration may be between 30 seconds and 3600 seconds, for example between 30 seconds and 2700 seconds, for example between 30 seconds and 1800 seconds. The duration may be between 60 seconds and 3600 seconds, for example between 60 seconds and 2700 seconds, for example between 60 seconds and 1800 seconds. The duration may be between 600 seconds and 3600 seconds, for example between 600 seconds and 2700 seconds, for example between 600 seconds and 1800 seconds. The duration may be between 900 seconds and 3600 seconds, for example between 900 seconds and 2700 seconds, for example between 900 seconds and 1800 seconds. The duration may be between approximately 30 seconds and approximately 3600 seconds. The heating element, for example the heater mat, may, advantageously, increase the temperature of the one of the first component and the second component to a temperature that is adequate to increase the temperature of the adhesive to a temperature at which the bonds of the adhesive are weakened relatively quickly. The method of decoupling the components of the battery assembly is thus efficient. In an embodiment, the heating element, for example the heater mat, may include a temperature sensor. The method may include detecting a temperature of the one of the first component and the second component using the temperature sensor. The temperature sensor advantageously allows the temperature of the one of the first component and the second component to be detected, thereby allow a user to monitor whether or not the heated one of the first component and the second component is within the required temperature range. The temperature sensor may be integrated into the heating element, for example the heater mat. In other words, the temperature sensor may be in-built into the heating element. In other embodiments of the invention, the temperature sensor may be accommodated within a pocket or a pouch on the heating element, for example the heater mat. In other words, the temperature sensor may be removable. The temperature sensor may be a contact temperature sensor, that is a temperature sensor that is in direct contact with the one of the first component and the second component. Alternatively, the temperature sensor may be a non-contact temperature sensor. In other words, the temperature sensor may measure radiation of heat from the heating element, for example the heater mat. In embodiments of the invention, the temperature sensor may be a resistance temperature detector (a resistance thermometer), a thermocouple sensor, a thermistor sensor, e.g. a negative temperature coefficient thermistor, an infra red sensor or a semiconductor-based sensor. Advantageously, the temperature sensor may be selected to provide the required level of accuracy and to ensure a fast response time. The heating element, for example the heater mat, may include a controller. The step of increasing the temperature of the one of the first component and the second component using the heating element may include setting an operating temperature of the heating element using the controller. The controller beneficially enables the temperature of the heating element, for example the heater mat, to be set at the required operating temperature to ensure that the temperature of the one of the first component and the second component is increased to the desired temperature range. In embodiments, the controller may be used to alter the operating temperature of the heating element, for example in response to the detected temperature of the one of the first component and the second component. The controller may, for example, automatically alter or change the operating temperature of the heating element, for example the heater mat, in response to the detected temperature of the one of the first component and the second component. The controller advantageously enables the operating temperature to be set at a temperature that provides the required level of heating. The controller may also be used to fine tune the operating temperature of the heating element to improve the efficiency and / or effectiveness of the decoupling process. By automating the adjustment of the operating temperature, the efficiency of the process may be further enhanced. The controller may be a temperature controller, for example a thermostat or a digital temperature controller. The outer surface of the first component may be a top surface of the first component and the inner surface of the first component may be a bottom surface of the first component. The top surface (outer surface) of the first component and the bottom surface (inner surface) of the first component may be referred to as opposing surfaces. The inner surface of the second component may be a top surface of the second component and the outer surface of the second component may be a bottom surface of the second component. The top surface (inner surface) of the second component and the bottom surface (outer surface) of the second component may be referred to as opposing surfaces. The first component and the second component may be vertically stacked such that the bottom surface of the first component is coupled to the top surface of the second component by the adhesive. In embodiments of the invention, the heating element, for example the heater mat, is applied to the top surface (outer surface) of the first component. The heating element, for example the heater mat, is used to increase the temperature of the first component and therefore the temperature of the adhesive between the bottom surface (inner surface) of the first component and the top surface (inner surface) of the second component. Optionally, the battery assembly may include a third component. The third component may include a top surface and an opposing bottom surface. The third component may be vertically stacked with the second component such that the bottom surface of the second component is coupled to the top surface of the third component using an adhesive. In embodiments of the invention, the heating element, for example the heater mat, may be removed from the top surface (outer surface) of the first component and the first component may be decoupled from the second component. The method may include applying the or another heating element, for example the or another heater mat, to the second component and increasing the temperature of the second component using the or the another heating element. By increasing the temperature of the second component, the temperature of the adhesive between the second component and the third component may be increased by conduction of heat from the heating element to the adhesive between the second component and the third component via the second component. In this way, the adhesive between the second component and the third component may be weakened. The method may advantageously be used to decouple more than one component from the battery assembly. The components may be decoupled in sequence, beneficially enabling the battery assembly to be disassembled. The method may include removing the or the another heating element, for example the or the another heater mat, from the second component and the decoupling the second component from the third component. In embodiments, the battery assembly may include a fourth component, wherein the fourth component comprises a top surface and an opposing bottom surface. The fourth component may be vertically stacked with the third component such that the bottom surface of the third component is coupled to the top surface of the fourth component using a further adhesive. In embodiments of the invention, the heating element, for example the heater mat, may be removed from the top surface of the second component and the second component may be decoupled from the third component. The method may include applying the or another heating element, for example the or another heater mat, to the top surface of the third component and increasing the temperature of the third component using the orthe another heating element. By increasing the temperature of the third component, the temperature of the adhesive between the third component and the fourth component may be increased by conduction of heat from the heating element to the adhesive between the third component and the fourth component via the third component. In this way, the adhesive between the third component and the fourth component may be weakened. The method may include removing the or the another heating element, for example the or the another heater mat, from the third component and the decoupling the third component from the fourth component. In embodiments of the invention the first component, the second component, the third component and the fourth component may be any component of a battery assembly that is coupled to another component of a battery assembly using an adhesive. The first component, the second component, the third component and the fourth component may be a structural component of a housing or an enclosure of the battery assembly. The first component may, for example, be a lid of a housing or an enclosure of the battery assembly and the second component may be a cross beam. The heating element may, in examples of the invention, be placed over the cross beam sealing location of the battery assembly, such that the adhesive between the cross beam and the lid is heated up and weakened. It will be appreciated that, in embodiments of the invention, the battery assembly may include any number of components that are coupled together using an adhesive. It will also be appreciated that, in embodiments of the invention, the components of the battery assembly may be stacked horizontally, and the heating element, for example the heater mat, may be applied to a side surface of the component in order to increase the temperature of the adhesive between horizontally stacked components of the battery assembly. Within the scope of this application, it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and / or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and / or features of any embodiment can be combined in anyway and / or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim, accordingly, including the right to amend any originally filed claim to depend from and / or incorporate any feature of any other claim although not originally claimed in that manner. BRIEF DESCRIPTION OF THE DRAWINGS One or more embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which: FIG. 1A shows a schematic representation of a battery assembly to which a heater mat has been applied in accordance with an embodiment of the invention; FIG. 1B shows an alternative view of the battery assembly and heater mat of FIG. 1A; FIG. 2 shows a schematic representation of a heater mat for use in a method according to an embodiment of the invention; and FIG. 3 shows a flow chart for a battery decoupling method according to an embodiment of the invention. DETAILED DESCRIPTION A battery decoupling method 300 in accordance with the present invention is described herein with reference to accompanying FIG. 1A to FIG. 3. Referring now to FIG. 1A and FIG. 1B, there is a battery assembly 100, for example a battery assembly 100 for an electric vehicle. The battery assembly 100 includes a first component 102 and a second component 104. The first component 102 and the second component 104 are vertically stacked and there is a layer of adhesive 106 between the two components 102, 104. A heating element 108, in the form of a heater mat, is positioned on top of the vertically stacked components 102, 104. The first component 102 which may be, for example, a lid of an enclosure of the battery assembly 100, has an outer surface 110 and an opposing inner surface 112. As shown in FIG. 1A, the outer surface 110 is a top surface of the first component 102 and the inner surface 112 is a bottom surface of the first component 102. The second component 104, which may be a structural component of the battery assembly 100 for example a cross beam, has an outer surface 114 and an opposing inner surface 116. As shown in FIG. 1A, the outer surface 114 is a bottom surface of the second component 104 and the inner surface 116 is a top surface of the second component 104. Each of the first component 102 and the second component 104 is generally rectangular in cross section and has a length 118 and a width 120. In the vertical stack, the outer surface 110 of the first component 102 faces the outside of the battery assembly 100 and the inner surface 112 of the first component 102 faces the inner surface 116 of the second component 104. Similarly, the outer surface 114 of the second component 104 faces the outside of the battery assembly 100 and the inner surface 116 of the second component 104 faces the inner surface 112 of the first component 102. The battery assembly 100 includes a layer of adhesive 106, which may be, for example a wet applied structural adhesive. The layer of adhesive 106 is provided on the inner surface 112 of the first component 102 and the inner surface 116 of the second component 104 such that the first component 102 is adhered, or coupled, to the second component 104. As shown in FIG. 1A and FIG. 1B, a heating element 108 is applied to the outer surface 110 of the first component 102 of the battery assembly 100. It will be appreciated that, in other embodiments of the invention, the heating element 108 may be applied to the outer surface 114 of the second component 104 of the battery assembly 100. As can be seen in FIG. 1B and FIG. 2, the heating element 108 is also generally rectangular in cross section and has a length 118 and a width 120. It will be noted that the cross-sectional shape and the size conforms to the cross-sectional shape and the size of the first component 102 and the second component 104 of the battery assembly 100. This advantageously improves the efficiency with which the first component 102 of the battery assembly 100 is heated by the heating element 108. The heating element 108 is a heater mat that is made from a flexible, silicone material. With particular reference to FIG. 2, it can be seen that the heating element 108 includes a temperature sensor 202 and a controller 204. The temperature sensor 202 is integrated within the heating element 108. The controller 204 is configured to receive temperature data from the temperature sensor 202 and determine whether the temperature of the component to which the heating element is applied is within the required operating temperature range. The controller 204 includes processing means and memory means. The processing means may be one or more electronic processing device which operably executes computer-readable instructions. The memory means may be one or more memory device. The memory means is electrically coupled to the processing means. The memory means is configured to store instructions, and the processing means is configured to access the memory means and execute the instructions stored thereon. The controller 204 also includes an input means and an output means. The input means may include an electrical input of the controller 204. The output means may comprise an electrical output of the controller 204. The input is arranged to receive a temperature signal from the temperature sensor 202. The temperature signal is an electrical signal which is indicative of the temperature of the component to which the heating element is applied. The output is arranged to output a temperature control signal that is indicative of the desired operating temperature for controlling the temperature of the heating element. A battery decoupling method 300 will now be described with reference to FIG. 3. In a first step 302, a heating element 108 is applied to an outer surface 110, for example to a surface of the first component 102 of the battery assembly 100 as shown in FIG. 1A and FIG. 1B. In a second step 304, the temperature of the first component 102 is increased using the heating element 108. In a third step 306, heat from the first component 102 is conducted through the first component 102 to the adhesive 106 between the first component 102 and the second component 104. The first component 102 thus increases the temperature of the adhesive 106. In other words, the adhesive 106 is indirectly heated using the heating element 108. When the adhesive 106 is heated, the adhesive bonds are weakened, the adhesive 106 becomes softer and thus the bond between the first component 102 and the second component 104 is also weakened. In step 308, the first component 102 is decoupled from the second component 104. Because the strength of the adhesive 106 between the first component 102 and the second component 104 has been weakened, the process of decoupling the first component 102 from the second component 104 requires less force and the risk of either of the components, or any other components of the battery assembly, becoming damaged is reduced. The first component 102 may, for example be decoupled from the second component 104 by the insertion of wedges along the lines of adhesive 106 between the first component 102 and the second component 104. In optional step 310, a temperature of the component to which the heating element 108 is applied (the first component 102) is detected before the temperature of the heating element 108 is increased in orderto increase the temperature of the first component 102 in step 304. Step 304 may also include setting an operating temperature of the heating element 108 using the controller 204. The operating temperature of the heating element 108 is altered using the controller in response to the detected temperature of the component. For example, the operating temperature may be altered automatically by the controller 204 in response to the detected temperature of the first component 102. In optional step 312, the heating element 108 is removed from the first component 102. Steps 302 to 312 may then be repeated to decouple additional components from the battery assembly. In a first repeated step 302, a heating element 108 is applied to a top surface of the second component 104 of the battery assembly 100. In a second repeated step 304, the temperature of the second component 104 is increased using the heating element 108. In a third repeated step 306, heat from the second component 104 is conducted through the second component 104 to the adhesive 106 between the second component 104 and the third component. The second component 104 thus increases the temperature of the adhesive 106 between the second component 104 and the third component. When the adhesive 106 between the second component 104 and third component is heated, the adhesive bonds are weakened, the adhesive 106 becomes softer and thus the bond between the second component 104 and the third component is also weakened. In step 308, the second component 104 is decoupled from the third component. Because the strength of the adhesive 106 between the second component 104 and the third component has been weakened, the process of decoupling the second component 104 from the third component requires less force and the risk of either of the components, or any other components of the battery assembly, becoming damaged is reduced. In optional repeated step 310, a temperature of the component to which the heating element 108 is applied (the second component 104) is detected before the temperature of the heating element 108 is increased in order to increase the temperature of the second component 104 in step 304. Repeated step 304 may also include setting an operating temperature of the heating element 108 using the controller 204. The operating temperature of the heating element 108 is altered using the controller in response to the detected temperature of the component. For example, the operating temperature may be altered automatically by the controller 204 in response to the detected temperature of the second component 104. In optional repeated step 312, the heating element 108 is removed from the second component 104. It will be appreciated that various changes and modifications can be made to the present invention without departing from the scope of the present application. In the embodiment of FIG. 1A and FIG. 1B, the first component 102 is a lid of a housing or an enclosure of the battery assembly and the second component 104 is a cross beam. It will be appreciated that, in other embodiments of the invention, the first component and / orthe second component may be different components of a battery. The first component and / orthe second component may be, forexample, any structural component of a housing or an enclosure of the battery assembly. In the embodiment described with reference to FIG. 1A and FIG. 1B, the battery assembly includes a first component and a second component. It will be appreciated that, in alternative embodiments of the invention, the battery assembly may include any number of components that are coupled together using an adhesive. The method of the present invention may be used to decouple one, two, three, four or any number of components from a battery assembly. Steps 302 to 312 may, forexample, be further repeated to decouple additional components from the battery assembly, for example to remove a third component from a fourth component. In a further repeated step 302, a heating element 108 is applied to a top surface of the third component of the battery assembly. In a further repeated step 304, the temperature of the third component is increased using the heating element. In a further repeated step 306, heat from the third component is conducted through the third component to the adhesive between the third component and the fourth component. The third component thus increases the temperature of the adhesive between the third component and the fourth component. When the adhesive between the third component and fourth component is heated, the adhesive bonds are weakened, the adhesive becomes softer and thus the bond between the third component and the fourth component is also weakened. In a further step 308, the third component is decoupled from the fourth component. Because the strength of the adhesive between the third component and the fourth component has been weakened, the process of decoupling the third component from the fourth component requires less force and the risk of either of the components, or any other components of the battery assembly, becoming damaged is reduced. In optional further repeated step 310, a temperature of the component to which the heating element is applied (for example the third component) is detected before the temperature of the heating element is increased in order to increase the temperature of the third component in step 304. Further repeated step 304 may also include setting an operating temperature of the heating element using the controller. The operating temperature of the heating element is altered using the controller in response to the detected temperature of the component. For example, the operating temperature may be altered automatically by the controller in response to the detected temperature of the third component. In optional further repeated step 312, the heating element is removed from the third component. In the embodiment described with reference to FIG. 1A and FIG. 1B, the first component and the second component of the battery assembly are stacked vertically. It will be appreciated that, in alternative embodiments of the invention, the components of the battery assembly may be stacked horizontally, and the heating element, for example the heater mat, may be applied to a side surface of the component in order to increase the temperature of the adhesive between horizontally stacked components of the battery assembly. In the embodiment described with reference to FIG. 1A and FIG. 1B, the adhesive is a wet applied structural adhesive. It will be appreciated that, in alternative embodiments of the invention, the adhesive may be a tape or pad adhesive. The battery assembly 100 described with reference to FIG. 1A and FIG. 1B is generally rectangular in cross section, as are each of the first component 102, the second component 104 and the heating element 108. It will be appreciated that, in other embodiments of the invention, the components of the battery assembly may be any shape in cross section and that the heating element 108 will be selected in a shape and size that conforms, as far as is practical to the shape and size of the components to be decoupled. In the example described with reference to FIG. 2, the heating element 108 is made from a flexible silicone material. It will be appreciated that, in other examples of the invention, the heating element may be made from any suitable materials including, for example, polyester, polyimide (e.g. Kapton) and silicate (e.g. mica). In the embodiment described with reference to FIG. 2, the temperature sensor 202 is integrated within the heating element 108. It will be appreciated that, in other examples of the invention, the temperature sensor is a separate component that is, for example, accommodated within a pouch ora pocket of the heating element. In the described embodiment, a controller 204 is used to automatically alter the temperature output of the heating element in the event the temperature of the component to which the heating element is applied is too high (hot) or too low (cold). It will be appreciated that, in other examples of the invention, the operating temperature of the heating element may be manually altered by an operator in the event the temperature of the component to which the heating element is applied is detected to be too hot or too cold.

Claims

1. A method of decoupling a first component of a battery assembly from a second component of the battery assembly, wherein an inner surface of the first component is coupled to an inner surface of the second component using an adhesive, and wherein the method comprises:applying a heating element to an outer surface of one of the first component and the second component;increasing a temperature of the one of the first component and the second component using the heating element; andincreasing a temperature of the adhesive between the first component and the second component using the one of the first component and the second component.

2. The method of claim 1, comprising decoupling the first component from the second component.

3. The method of claim 1 or 2, wherein increasing the temperature of the one of the first component and the second component using the heating element comprises electrically heating the one of the first component and the second component.

4. The method of claim 1, claim 2 or claim 3, wherein the heating element is a heater mat, and wherein the step of applying the heating element to the outer surface of the one of the first component and the second component comprises:applying the heater mat to the outer surface of the one of the first component and the second component.

5. The method of any one of claims 1 to 4, wherein the heating element is sized such that a length and a width of the heating element is at least the same as a length and a width of the one of the first component and the second component.

6. The method of any one of claims 1 to 5, wherein the temperature of the one of the first component and the second component is increased to between approximately 60°C and approximately 130°C.

7. The method of any one of claims 1 to 6, wherein the temperature of the adhesive is increased to between approximately 30°C and approximately 90°C.

8. The method of any one of claims 1 to 7, wherein the step of increasing the temperature of the one of the first component and the second component using the heating element has a duration, and wherein the duration is between approximately 30 seconds and approximately 3600 seconds.

9. The method of any one of claims 1 to 8, wherein the heating element comprises a temperature sensor, and the method comprises:detecting a temperature of the one of the first component and the second component using the temperature sensor.

10. The method of claim 9, wherein the heating element comprises a controller, and the step of increasing the temperature of the one ofthe first component and the second component using the heating element comprises: setting an operating temperature ofthe heating element using the controller, andusing the controller to alter the operating temperature of the heating element in response to the detected temperature ofthe one ofthe first component and the second component.

11. The method of claim 10, wherein the controller automatically alters the operating temperature ofthe heating element in response to the detected temperature ofthe one ofthe first component and the second component.

12. The method of any one of claims 1 to 11, wherein the outer surface ofthe first component is a top surface ofthe first component, the inner surface ofthe first component is a bottom surface ofthe first component, and the inner surface ofthe second component is a top surface ofthe second component, and wherein the second component further comprises a bottom surface, wherein the bottom surface ofthe first component is coupled to the top surface ofthe second component using the adhesive such that the first component and the second component are vertically stacked, and wherein the method further comprises:applying the heating element to the top surface ofthe first component;increasing the temperature ofthe first component using the heating element for increasing the temperature of the adhesive.

13. The method of claim 12, wherein the battery assembly comprises a third component, wherein the third component comprises a top surface, and wherein the bottom surface ofthe second component is coupled to the top surface ofthe third component using a further adhesive such that the second component and the third component are vertically stacked, the method comprising:removing the heating element from the top surface ofthe first component;decoupling the first component from the second component;applying the or another heating element to the top surface ofthe second component;increasing the temperature ofthe second component using the or the another heating element;increasing the temperature ofthe further adhesive between the second component and the third component using the second component.

14. The method of claim 13, wherein the third component comprises a bottom surface and wherein the battery assembly comprises a fourth component, wherein the fourth component comprises a top surface, and the bottom surface ofthe third component is coupled to the top surface ofthe fourth component using a further adhesive such that the third component and the fourth component are vertically stacked, the method comprising:removing the heating element from the top surface ofthe second component;decoupling the second component from the third component;applying the or another heating element to the top surface ofthe third component;increasing the temperature ofthe third component using the or the another heating element;increasing the temperature ofthe further adhesive between the third component and the fourth component using the third component.18

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