Battery Cell Stack Solvent-Free Resin Layer
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Solution Overview
Problem
The manufacturing of battery cell stacks for high-output hybrid vehicles and electric vehicles is hindered by the need for complex and costly fastening and cooling systems, which increase weight and volume, and the tape-based adhesive methods are inefficient due to process complexity and waste generation, as well as difficulties in rework and reuse.
Innovation Solution
A battery cell stack with a solvent-free resin layer, comprising a pressure-sensitive adhesive, applied through spray coating or slot die coating, which provides structural stability, reliability, and improved reworkability, while simplifying materials and processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If tape type adhesive is used to attach battery cells, then the manufacturing process becomes more complex and generates waste, but the adhesive application is simpler
Solution Approach 1:
The patent extracts and eliminates the release paper component from the adhesive system. By using a solvent-free adhesive that can be applied directly without a release layer, the manufacturing process is simplified while reducing waste generation. The adhesive is applied in a controlled manner directly to the battery cell surfaces, removing the need for separate release paper handling steps.
Solution Approach 2:
The patent eliminates the disposable release paper by using a solvent-free adhesive system that bonds directly to the battery cell surfaces. This removes the need for single-use release papers that generate waste, while maintaining ease of adhesive application through direct bonding.
2Ease of manufacture
If tape type adhesive is used to attach battery cells, then the adhesive application process is simpler, but rework becomes difficult and reuse is impossible
Solution Approach 1:
The patent utilizes the temperature-dependent properties of the solvent-free adhesive. At elevated temperatures, the adhesive becomes softer and more pliable, allowing for easy removal and rework. At normal operating temperatures, it provides strong bonding. This parameter change enables both easy application and easy rework/removal of the adhesive.
3Power
If fastening parts and cooling equipment are added to increase battery capacity and output, then the battery performance improves, but the volume and weight increase
Solution Approach 1:
The patent merges the adhesive function with the structural bonding function. The solvent-free adhesive serves both to bond battery cells together and to provide structural stability, eliminating the need for separate fastening parts. This integration reduces the overall weight and volume of the battery pack while maintaining the required structural integrity for high power output.
4Power
If fastening parts and cooling equipment are added to increase battery capacity and output, then the battery performance improves, but the manufacturing cost increases
Solution Approach 1:
The patent combines multiple functions into the solvent-free adhesive system, which provides both bonding and structural support. This eliminates the need for separate fastening parts and reduces the complexity of cooling equipment integration, thereby lowering manufacturing costs while maintaining high battery output capability.
Solution Approach 2:
The solvent-free adhesive serves multiple functions simultaneously: it bonds battery cells together, provides structural stability, and facilitates heat management. This multi-functionality reduces the need for additional components, simplifying manufacturing and reducing costs while supporting high power battery configurations.
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 solvent-free resin layer enhances the structural stability and reliability of the battery cell stack, reduces manufacturing complexity, and allows for easier rework and recycling, minimizing damage and increasing productivity.
Implementation Method 1
a resin layer which is wholly or partially in contact with an outer surface of at least one of the plurality of battery cells... formed of a resin layer composition including a solvent-free adhesive
Implementation Method 2
the solvent-free adhesive may be a pressure sensitive adhesive (PSA)
Data Source
AI summary
A battery cell stack of the present invention includes a plurality of battery cells and a resin layer wholly or partially in contact with an outer surface of at least one of the plurality of battery cells, wherein the resin layer includes a solvent-free adhesive, and has specific peel strength and shear strength, such that the resin layer may be applied by a spray coating, and thereby improving structural stability and reliability of the battery cell stack, while simplifying materials and processes necessary to manufacture the battery cell stack.