Secondary Battery Adhesive Bonding for Accessory Unit Assembly
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Solution Overview
Problem
The existing methods for assembling secondary batteries with protective circuit modules result in weak bond strength between the bare cell and the accessory unit, cumbersome resin mold processes, and non-uniform resin filling, leading to inefficient manufacturing and recyclability issues.
Innovation Solution
The use of an adhesive member, such as a thermosetting adhesive or photo-curing adhesive, to affix the accessory unit with a protective circuit module directly to the bare cell, eliminating the need for complex resin molding and allowing for easier assembly and disassembly, thereby enhancing bond strength and recyclability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If resin molding is used to assemble the bare cell with the protective circuit module, then the bond strength between components is improved, but the manufacturing process becomes cumbersome and time-consuming
Solution Approach 1:
The protective circuit module is extracted as a separate accessory unit that can be independently manufactured and then assembled to the bare cell using adhesive members, eliminating the need for complex resin molding processes while maintaining bond strength
Solution Approach 2:
The complex resin molding process is replaced with a simpler adhesive bonding system, where adhesive members are applied to attach the accessory unit to the bare cell, significantly simplifying the manufacturing process
2Strength
If resin is injected to fill the space between the bare cell and protective circuit module, then the components are securely bonded, but the resin filling becomes non-uniform and requires additional mold processes
Solution Approach 1:
The resin filling step is extracted and eliminated from the assembly process. Instead, adhesive members are applied directly to bond the accessory unit to the bare cell, ensuring uniform application without the complexity of mold-based resin injection
Solution Approach 2:
Adhesive members serve as an intermediary bonding agent between the bare cell and accessory unit, providing secure attachment without requiring resin injection and mold processes, thereby achieving uniform bonding
3Strength
If the accessory unit is permanently assembled with the bare cell using resin molding, then the bond strength is improved, but the recyclability and reuse of safety devices is reduced
Solution Approach 1:
The battery system is segmented into a bare cell and a separate accessory unit containing the protective circuit module. These segments are connected via adhesive members that provide sufficient bond strength during operation but allow for separation and recycling at the end of the battery's life
Solution Approach 2:
The bonding system transitions from a permanent resin mold to a dynamic adhesive bond that maintains structural integrity during use but allows for controlled separation and recycling, enabling the accessory unit to be reused with other bare cells
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 approach simplifies the assembly process, improves bond strength between the bare cell and accessory unit, and enables the reuse of safety devices, reducing manufacturing costs and environmental impact by allowing for the recycling of accessory units.
Implementation Method 1
an adhesive member arranged in at least a portion of facing surfaces of both the bare cell and the accessory unit
Data Source
AI summary
A secondary battery includes: a bare cell having an electrode assembly including two electrodes and a separator arranged between the two electrodes, a cell container having an opening and adapted to contain the electrode assembly, and a cap assembly adapted to cover the opening; and an accessory unit having a protective circuit module and adapted to be electrically connected to the bare cell via at least one electrode from outside of the bare cell. The accessory unit is adapted to be affixed to the bare cell with an adhesive member arranged in at least a portion of facing surfaces of both the bare cell and the accessory unit.