Battery Module Elastic Interlayer for Easier Cell Assembly
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Solution Overview
Problem
The existing methods for manufacturing battery modules using compression pads, such as urethane sheets, face difficulties due to size adjustments and static electricity issues, which decrease workability and require peeling off PET films, making the process cumbersome.
Innovation Solution
A battery module design incorporating a function material with elastic particles and a binder, where the elastic particle is a resinous hollow particle and the binder is an acrylic resin, applied as a slurry and cured, providing specific compression force deflection properties to improve handling and manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a compression pad is provided between adjacent battery cells, then the battery cells are held in position and protected, but the handling becomes difficult due to static electricity and the size must be changed according to battery cell size
Solution Approach 1:
The invention changes the material parameters from solid foam to liquid slurry containing elastic particles. This allows the material to be applied in a fluid state for easy handling and then transformed into a solid state for providing the required mechanical support and positioning, thereby resolving the contradiction between ease of handling and functional reliability
Solution Approach 2:
The compression pad material undergoes phase transition from liquid slurry to solid gel through curing. In liquid form, it is easy to apply and handle without static electricity issues. After curing, it provides the necessary mechanical properties for positioning and protecting battery cells, thus resolving the handling difficulty while maintaining functional reliability
2Reliability
If a compression pad is used, then the battery cells are secured, but the workability for manufacturing decreases due to the need to peel off PET film and adjust size
Solution Approach 1:
The invention changes the material from solid foam requiring size adjustment and film peeling to liquid slurry that can be directly applied and cured in place. This eliminates the need for size adjustment and film removal steps, improving manufacturing workability while maintaining the securing function
Solution Approach 2:
The liquid slurry material is applied directly to the battery cell surface and cures in place to form the compression pad. The material serves itself by being applied in its final location and transforming there, eliminating the need for separate size adjustment and film removal operations, thus improving ease of manufacture
3Area of stationary object
If the size of the compression pad increases to match larger battery cells, then the coverage and protection are improved, but the handling becomes more difficult due to static electricity
Solution Approach 1:
The material is applied in liquid slurry form which is easy to handle regardless of area size, then cures to the required size. This phase transition allows large area coverage to be achieved without the handling difficulties associated with large static-charged foam sheets
Solution Approach 2:
The invention uses liquid slurry (hydraulic principle) instead of solid foam, allowing the material to flow and conform to the required area without static electricity issues. The liquid state enables easy application over large areas, and curing provides the necessary structural properties
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 solution enhances workability by allowing easier application and curing of the function material between battery cells, reducing shear stress and load on electrodes, and improving the overall manufacturing process efficiency.
Implementation Method 1
in the step of curing the binder, the binder is cured by irradiating the binder with light
Implementation Method 2
a compression force deflection at 25° C. and 10% deflection of the function material is equal to or more than 3.0 kPa and equal to or less than 10 kPa
Data Source
AI summary
A battery module includes a plurality of battery cells and a function material. The function material is located between adjacent battery cells. The function material includes an elastic particle and a binder. The elastic particle is dispersed in the binder.