Battery Cell Array Compression Joining Without Spacers
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Solution Overview
Problem
The existing battery manufacturing method is complicated, leading to decreased productivity and increased battery size due to the need for custom spacers and binding jigs, which also results in higher manufacturing costs and reduced yield and reliability.
Innovation Solution
A manufacturing method that eliminates the use of spacers by applying a load to bind the cell array using a second end member, which is integrally molded with the case, allowing for a more efficient and cost-effective production process while maintaining the binding load and size management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If spacers and binding jigs are used to bind the cell array, then the binding load is achieved, but the manufacturing process becomes complicated and productivity decreases
Solution Approach 1:
The invention removes the spacers from the battery structure, extracting the problematic element that caused manufacturing complexity. The cell array is bound directly by the end members without requiring separate spacer components, thereby simplifying the manufacturing process while maintaining binding functionality.
Solution Approach 2:
The end members are designed to serve multiple functions: they provide structural closure for the battery case and simultaneously apply the binding load to the cell array. This multi-functionality eliminates the need for separate binding jigs and spacers, improving productivity while maintaining reliability.
2Reliability
If spacers and clamping spacers are used to bind the cell array, then the binding load is achieved, but the battery size increases
Solution Approach 1:
The invention extracts the spacers and clamping spacers from the battery structure, removing the additional volume these components occupied. The cell array is bound directly by the end members, eliminating the space required for separate spacer components and reducing overall battery size.
Solution Approach 2:
The binding function previously performed by separate spacer components is merged into the end members themselves. The end members directly contact and bind the cell array, combining the structural and binding functions into a single component, thereby reducing battery volume.
3Reliability
If binding jigs are used to bind the cell array, then the binding load is achieved, but the battery size increases
Solution Approach 1:
The invention removes the binding jigs from the final battery structure, extracting the temporary tooling that added to battery size. The end members are designed to directly apply the binding load without requiring external binding jigs, thereby reducing battery volume.
Solution Approach 2:
The end members are designed to perform both the structural closure function and the binding function simultaneously, eliminating the need for separate binding jigs. This multi-functionality reduces the number of components and decreases battery size.
4Ease of manufacture
If a load greater than binding load is temporarily applied during insertion, then the cell array is secured, but yield and reliability decrease
Solution Approach 1:
The end members are pre-positioned in the case before the cell array is inserted. This preliminary arrangement ensures that when the cell array is inserted, the binding load is applied gradually and uniformly from the start, preventing the need for temporary high-load application that could damage the cells and reduce yield.
Solution Approach 2:
The end members are designed to automatically apply the appropriate binding load as the cell array is inserted, without requiring external binding jigs or manual load application. The structure itself provides the binding function, ensuring consistent and controlled load application that protects cell integrity and maintains high yield.
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 enhances battery productivity, reduces the size and cost of the end product, and stabilizes the joining process to prevent yield and reliability issues, all while eliminating the need for additional spacers and binding jigs.
Implementation Method 1
joining each of the compartment members with the second end member at a second end in the longitudinal direction while applying a load to bind the cell array in a direction to compress the cell array from an outside part of the second end member
Data Source
AI summary
A manufacturing method for a battery including a cell array and a case is provided. The cell array includes a plurality of single cells arranged in a certain direction. The case includes a pair of compartment members of which a longitudinal direction is a direction in which the single cells are arranged, and a first end member provided at a first end in the longitudinal direction. In the manufacturing method, in space surrounded by the compartment members and the first end member, the cell array and a second end member facing the first end member across the cell array are placed. In a direction to compress the cell array from an outside part of the second end member, each compartment member is joined with the second end member at a second end in the longitudinal direction while a predetermined load is applied to bind the cell array.