Battery Cell Block Contact Protection Using Foaming Adhesive
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Solution Overview
Problem
Existing methods for providing electrical insulation in battery assemblies, such as those for electric vehicles, are complex due to the assembly of plastics-molded components, which is time-consuming and inefficient.
Innovation Solution
A method involving the use of a foaming adhesive applied to the battery cell block top side, which expands to form a contact protection, simplifying the assembly process by ensuring electrical contacts are insulated before the battery cell block is removed from the mold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If plastics-molded components are assembled to provide electrical insulation, then contact protection is achieved, but the assembly process becomes very complex and time-consuming
Solution Approach 1:
The invention extracts the electrical insulation function from complex plastics-molded components and implements it through a simple foaming adhesive material applied directly to the battery cell block, eliminating the need for separate insulation components and their complex assembly
Solution Approach 2:
The invention changes the physical state and properties of the adhesive material by using foaming adhesive that expands after application, transforming from a liquid/gel state to a solid foam structure that provides insulation, thereby simplifying the overall assembly process
2Reliability
If plastics-molded components are assembled to provide continuous sheathing, then contact protection is improved, but the assembly process becomes very complex
Solution Approach 1:
The foaming adhesive material performs multiple functions automatically: it adheres battery cells together, provides electrical insulation, and creates continuous sheathing protection without requiring separate assembly steps for each function, enabling the system to self-service its own manufacturing needs
3Reliability
If individual terminals and connectors are insulated with pre-assembled sheaths, then contact protection is provided, but the overall assembly complexity increases
Solution Approach 1:
The invention merges the insulation function with the adhesive bonding function into a single material system, where the foaming adhesive simultaneously bonds battery cells and provides electrical insulation, eliminating the need for separate pre-assembled insulation sheaths on individual terminals
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 method provides effective electrical contact protection with reduced cycle time and increased safety, eliminating the need for complex plastics-molded components, thus enhancing production efficiency and safety.
Implementation Method 1
applying a foaming adhesive onto or into a mold; positioning the battery cell block on or in the mold and inserting the battery cell block top side into the foaming adhesive
Data Source
AI summary
A method for producing a battery assembly for a battery module, comprising the following steps: providing a battery cell block comprising a plurality of battery cells, where a battery cell block top side has one or more electrical contacts (of the plurality of battery cells; applying a foaming adhesive onto or into a mold; positioning the battery cell block on or in the mold and inserting the battery cell block top side into the foaming adhesive so that the battery cell block top side is at least partially wetted by the foaming adhesive in order to form contact protection for the battery cell block top side by means of the foaming adhesive; waiting until the foaming adhesive adheres to the battery cell block top side; and removing the battery cell block from or out of the mold.