Additive Manufacturing Partitions for Electrochemical Element Assembly
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Solution Overview
Problem
Existing methods for assembling electrochemical elements, such as mechanical connections and resin casting, face limitations including prefabrication requirements, tool investment, resin leaks, air pockets, and restricted geometry, which can lead to damage and poor thermal protection.
Innovation Solution
An additive manufacturing technique is used to deposit layers of structural material, forming partitions between electrochemical elements, allowing for flexible geometry and improved assembly without additional mechanical connections, while enabling the creation of air channels and varying material properties for enhanced thermal insulation and mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If mechanical connection means are used to assemble electrochemical elements, then the elements can be held together securely, but prefabrication of parts and investment in manufacturing tools are required, and geometries are limited to selected methods
Solution Approach 1:
The patent merges the structural support function and the assembly function into a single integrated component. The additive manufacturing process creates a monolithic structure that simultaneously provides mechanical support and secures multiple electrochemical elements, eliminating the need for separate prefabricated connection means and tools.
Solution Approach 2:
The invention changes the manufacturing approach from traditional subtractive or assembly-based methods to additive manufacturing. This parameter change enables complex geometries to be created directly during the manufacturing process without requiring prefabrication, special tools, or limiting the design to selected geometric configurations.
2Stability of the object's composition
If resin casting is used to assemble elements in a block, then the elements are held together as one block, but resin leaks are observed and air pockets can form that cause poor thermal protection
Solution Approach 1:
The additive manufacturing process deposits material in successive layers, segmenting the manufacturing process into controlled stages. This layer-by-layer approach prevents the formation of large air pockets that occur in resin casting, as each layer is carefully deposited and cured before the next layer is added, ensuring complete material placement without voids.
Solution Approach 2:
The invention replaces the chemical resin casting process with an additive manufacturing process that uses controlled material deposition and curing. This substitution eliminates the problems of resin leaks and air pocket formation associated with pouring large volumes of liquid resin, while still achieving a solid block structure with reliable thermal protection.
3Quantity of substance
If a large volume of resin is poured into a box, then the elements are fully surrounded, but the setting time is long which affects productivity
Solution Approach 1:
The additive manufacturing process uses periodic action by depositing material in successive layers with controlled curing between each layer. This periodic deposition and curing cycle allows the process to handle large volumes of material efficiently, as each layer is processed independently and quickly, avoiding the long single-stage setting time required for large volume resin pouring.
4Stability of the object's composition
If casting is used to assemble elements, then the elements are encased in a block, but complex geometries useful for battery performance cannot be created
Solution Approach 1:
The invention changes the manufacturing methodology from conventional casting to additive manufacturing. This fundamental parameter change enables the creation of complex geometries including channels, cavities, and varied cross-sections that are impossible to achieve with traditional casting, while still producing a solid block structure that provides stable support and protection for the electrochemical elements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method reduces manufacturing time, minimizes material leaks and air pockets, allows for complex geometries, and enhances thermal insulation and mechanical strength, facilitating the assembly of large or complex electrochemical element configurations.
Implementation Method 1
A first layer of a bead of structural material is deposited in contact with one of the elements. We expect its total or partial solidification (or its cohesion in the case of a structural material in the form of a powder).
Implementation Method 2
A first layer of a bead of structural material is deposited in contact with one of the elements. We expect its total or partial solidification (or its cohesion in the case of a structural material in the form of a powder).
Data Source
Figure 1~2a
Figure 2b
Figure 3a~4d
AI summary
The invention relates to an assembly of a plurality of electrochemical elements (1), in which the electrochemical elements comprise a container (5) having a side wall, said assembly being characterized in that at least one portion of the side wall of at least one of the containers is in contact with a partition obtained by means of an additive manufacturing method, and is produced by superposing at least two strips (4) of a structural material.