Battery Pack Adhesive Release Using Cooling Plate Heating
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Solution Overview
Problem
Modern automotive high voltage battery packs face challenges in disassembly due to large, inaccessible adhesive joints, which complicates service, remanufacturing, and recycling processes.
Innovation Solution
A thermally triggered adhesive release system is introduced, utilizing preexisting thermal management systems to apply targeted heating to adhesive joints, reducing adhesive strength and allowing for selective removal of components without damaging adjacent structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-strength adhesives are used to join battery components, then structural integrity and bond strength are improved, but disassembly and serviceability deteriorate
Solution Approach 1:
The adhesive's physical state is changed by controlling temperature parameters. During service, the adhesive is heated above its glass transition temperature to transition from a rigid bonded state to a softened removable state, enabling disassembly while maintaining strong bonding during normal operation
Solution Approach 2:
The adhesive is pre-configured with specific thermal properties (glass transition temperature) that enable future serviceability. The thermal management system is pre-integrated into the battery pack design to provide the necessary heating capability for adhesive softening during disassembly operations
2Temperature
If thermal management systems are integrated into battery packs, then thermal control capability is improved, but device complexity increases
Solution Approach 1:
The thermal management system performs dual functions: it provides necessary thermal control for battery operation during service, and simultaneously serves as the heating mechanism for adhesive softening during disassembly. This eliminates the need for separate heating systems, reducing overall complexity
Solution Approach 2:
The cooling and heating functions are merged into a single thermal management system. The same fluid channels and temperature control mechanisms used for battery cooling during operation are utilized for heating the adhesive during service, consolidating system components
3Reliability
If adhesives are used to retain battery cells during high acceleration events, then reliability is improved, but serviceability worsens
Solution Approach 1:
The adhesive's mechanical properties are dynamically changed through temperature control. During high acceleration events, the adhesive maintains its rigid bonded state for reliable cell retention. During service operations, heating above the glass transition temperature softens the adhesive, enabling easy cell removal and serviceability
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 enables the use of high-strength adhesives during the life of the battery pack, while allowing for controlled, thermally triggered adhesive release during end-of-life or service scenarios, minimizing waste and maintaining structural integrity.
Implementation Method 1
modifying at least one of a flowrate and a temperature of a heating fluid through the enclosed volume
Implementation Method 2
measuring a temperature of an adhesive layer coupled to the cooling plate
Data Source
AI summary
Aspects of the disclosure include systems and methods for leveraging a thermally triggered adhesive release for battery service. An exemplary method can include receiving a battery pack having an adhesive layer at an interface between a cooling plate and a component. A heating fluid is directed through an enclosed volume of the cooling plate and a temperature of the adhesive layer is measured. Responsive to determining that the temperature has reached a target temperature, a load is applied to the component until the component is removed.