Battery Module Cell Fixation via Adhesive Layers
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Solution Overview
Problem
Traditional mechanical fixation assemblies for battery modules are burdensome in terms of cost and weight, and cause stress on battery cells due to expansion and contraction during chemical reactions, leading to potential deformation, fracture, and reduced performance.
Innovation Solution
A battery module using adhesive layers to securely attach electrochemical cells to each other and to end plates and a base plate, distributing expansion forces and reducing peak stresses, while eliminating the need for welding and minimizing material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal restraint bands are used to mechanically fix battery cells, then structural support is provided, but weight and size of the module increase
Solution Approach 1:
The patent replaces the traditional mechanical restraint band system with a chemical bonding system using adhesive layers. The adhesive layers are applied between adjacent battery cells and between cells and end plates to provide fixation, eliminating the need for metal bands and their associated welding operations. This substitution directly reduces module weight while maintaining structural support.
2Strength
If metal restraint bands are used to mechanically fix battery cells, then structural support is provided, but manufacturing costs increase due to welding and assembly
Solution Approach 1:
The patent replaces the mechanical restraint band system with a chemical bonding system using adhesive layers. The adhesive layers are applied between adjacent battery cells and between cells and end plates to provide fixation, eliminating the need for metal bands and their associated welding operations. This substitution directly reduces module weight while maintaining structural support.
Solution Approach 2:
The patent employs adhesive layers that are simpler and less expensive to apply than metal restraint bands requiring welding. The adhesive material itself is a consumable that provides the necessary bonding without requiring additional fasteners or complex assembly tools, thereby reducing manufacturing costs.
3Stability of the object's composition
If metal restraint bands are used to fix battery cells, then cells are held together, but peak stresses concentrate at contact points causing deformation and fracture
Solution Approach 1:
The patent applies adhesive layers at multiple locations: between adjacent battery cells and between cells and end plates. This distributed bonding approach ensures that expansion forces are spread across the entire adhesive interface rather than concentrated at discrete contact points, preventing stress concentration that could lead to dielectric coating failure or casing fracture.
Solution Approach 2:
The adhesive layer acts as an intermediary material between the battery cells and end plates, and between adjacent cells. This intermediary layer compliantly accommodates cell expansion and contraction during cycling, distributing mechanical stresses uniformly and preventing direct rigid contact that would concentrate peak stresses at discrete points.
4Stability of the object's composition
If traditional mechanical fixation is used, then cells are secured, but the overall size of the battery module increases
Solution Approach 1:
The patent removes the external metal restraint band structure that traditionally surrounded and constrained battery cells. Instead, the fixation function is extracted and distributed into adhesive layers applied directly at the interfaces between cells and at cell-end plate interfaces, eliminating the need for additional structural components and reducing overall module volume.
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 solution reduces manufacturing costs and weight, enhances cell life and performance by distributing expansion forces, and provides improved thermal conductivity and electrical isolation.
Implementation Method 1
a first adhesive layer positioned between the first side plate and the first side, the first adhesive layer adhered to the first side plate and the first side through the first window
Data Source
AI summary
A battery module comprises an electrochemical cell including a first dielectric layer positioned on a first side of the cell, a first side plate in opposition to the first side, and a first adhesive layer positioned between the first side plate and the first side. The first dielectric layer defines a first window. The first adhesive layer is adhered to the first side plate and the first side through the first window. Another battery module comprises first and second cells, a base plate, a frame, and a first and second adhesive portion. The frame includes a beam positioned between the first cell and the second cell and is in engagement with a first side and a second side of the first and second cells, respectively. The first adhesive portion and the second adhesive portions are positioned between the base plate and the bottom surfaces of the cells.