Battery Cell Module Assembly With Adhesive Collector Plate Bonding
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Solution Overview
Problem
Existing battery pack designs face challenges in efficiently connecting and securing lithium-ion battery cells while minimizing the use of fasteners, ensuring robust electrical connections, and providing a means to monitor and manage battery life effectively.
Innovation Solution
The design of cell module assemblies featuring frames with protrusions forming pockets for battery cells, collector plates for electrical connection, and adhesive coupling, along with optional compression limiters and mating features for assembly, allows for secure, fastener-free connections and includes a battery monitoring system for life management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If adhesive coupling is used to connect battery cells to frames and collector plates, then the number of fasteners is reduced and assembly complexity is minimized, but the strength and reliability of the connection must be ensured
Solution Approach 1:
The patent replaces traditional mechanical fastening systems (screws, clips, or other fasteners) with an adhesive coupling system. The adhesive is applied to couple the battery cells to the frames and collector plates, eliminating the need for mechanical fasteners and simplifying the assembly process while maintaining connection integrity through chemical bonding rather than mechanical interlocking.
2Reliability
If multiple adhesive application points are used to contact battery cells in separate locations, then the reliability of electrical and mechanical connection is improved, but the manufacturing process complexity increases
Solution Approach 1:
The adhesive acts as an intermediary substance that simultaneously provides both mechanical bonding and electrical conductivity. By applying adhesive at multiple discrete points on the battery cell surfaces, the system achieves reliable multi-point contact that ensures both structural stability and electrical connectivity without requiring complex manufacturing equipment, as the adhesive self-distributes to fill gaps and create effective bonding surfaces.
3Stability of the object's composition
If battery cells are securely held in pockets formed by frame protrusions, then the stability of the battery module is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The frame protrusions are designed to automatically form pockets that self-align with the battery cells during assembly. The geometric configuration of the protrusions creates natural locating features that guide the battery cells into their correct positions, allowing the assembly process to be self-aligning and reducing the need for high-precision manufacturing tolerances. The adhesive then secures the cells in these self-aligned positions.
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 design enhances the stability and efficiency of battery packs by ensuring robust electrical connections, reducing assembly complexity, and enabling effective battery life management through adhesive coupling and integrated monitoring systems.
Implementation Method 1
The curable adhesive contacts the top frame and each of the multiple lithium-ion battery cells in at least two separate locations to adhesively couple each lithium-ion battery cell to the top frame
Implementation Method 2
The top collector plate is electrically connected to the multiple lithium-ion battery cells and is adhesively coupled to the top frame
Data Source
AI summary
A cell module assembly includes a first frame having a first plurality of pockets, a second frame spaced apart from the first frame and having a second plurality of pockets, a plurality of lithium-ion battery cells coupled to and extending between the second frame and the first frame, a first collector plate electrically connected to the plurality of lithium-ion battery cells and coupled to the first frame by a first curable adhesive, and a second collector plate electrically connected to the plurality of lithium-ion battery cells and coupled to the second frame by a second curable adhesive. Each one of the plurality of lithium-ion battery cells is received within a respective one of the first plurality of pockets and a respective one of the second plurality of pockets.