Battery Cell Assembly Using Spray-Coated Liquid Adhesive
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Solution Overview
Problem
Conventional double-sided tapes used in battery cell assemblies are prone to deterioration over time, leading to reduced adhesive strength and increased defects in the manufacturing process, which affects profitability.
Innovation Solution
A battery cell assembly that uses a one-component type liquid material, such as an alcohol-based or water-based adhesive/cohesive agent, to couple adjacent battery cells, replacing the need for double-sided tapes and allowing for improved stacking and integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If double-sided tape is used to couple battery cells, then adhesive strength is initially sufficient, but adhesive strength deteriorates over time leading to reduced reliability
Solution Approach 1:
The patent changes the chemical composition parameters of the adhesive material from conventional double-sided tape to a specifically formulated adhesive composition containing rubber resin, synthetic resin, and inorganic filler. This parameter change enables the adhesive to maintain its bonding strength throughout the entire service life of the battery module, resolving the deterioration issue of traditional tapes.
Solution Approach 2:
The patent employs a composite adhesive material combining multiple components: rubber resin (for flexibility and bonding), synthetic resin (for structural integrity), and inorganic filler (for stability and heat resistance). This composite formulation ensures the adhesive maintains its properties over time without deteriorating, thus improving both strength and duration of action.
2Ease of manufacture
If double-sided tape is used for battery cell coupling, then adhesive function is provided, but manufacturing defects increase due to tape transfer and stretching issues
Solution Approach 1:
The patent extracts the problematic double-sided tape component from the manufacturing process and replaces it with a liquid adhesive composition applied directly to the battery cell surfaces. This elimination of the tape component removes the source of manufacturing defects such as tape transfer and stretching, while still providing the necessary adhesive function through the liquid composition.
Solution Approach 2:
The patent replaces the mechanical double-sided tape system with a chemical adhesive system. Instead of using a pre-formed tape that requires mechanical application and is prone to physical defects, the invention uses a liquid adhesive composition that is applied and cured to create bonds, thereby eliminating mechanical application defects.
3Stability of the object's composition
If double-sided tape is used to maintain battery cell stability, then stacking stability is improved, but production cost increases due to continuous management requirements
Solution Approach 1:
The patent implements a self-service adhesive system where the liquid adhesive composition automatically provides stable bonding without requiring continuous external management or monitoring during the battery module's operation. The adhesive cures to form permanent bonds that maintain stacking stability autonomously, eliminating the need for ongoing tape management and reducing production costs.
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
The use of a one-component liquid material reduces defects associated with double-sided tapes, enhances space utilization in the manufacturing process, eliminates interference with mechanical devices, and lowers production costs while maintaining adhesive properties.
Implementation Method 1
battery cells adjacent to each other among the plurality of battery cells being coupled by a one-component material
Data Source
AI summary
A method of manufacturing a battery cell assembly in which a plurality of battery cells are stacked includes a step of coupling battery cells adjacent to each other among the plurality of battery cells using a one-component liquid material, wherein the one-component liquid material is coated onto at least one battery cell of the battery cells adjacent to each other by a spray-coating method.