Battery Module Case Coupling With Adhesive Interlock Assembly
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Solution Overview
Problem
Existing battery modules face issues with inadequate coupling force between internal components, high material cost, and inefficient manufacturing processes due to the use of bolts and nuts for assembly.
Innovation Solution
A battery module design featuring male-and-female coupling portions between module cases with an interposed adhesive, eliminating the need for bolts, and incorporating hooks, grooves, and spiral grooves for enhanced mechanical coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If bolts and nuts are used to couple module cases, then coupling force is sufficient, but material cost increases and manufacturing time increases
Solution Approach 1:
The patent replaces the mechanical fastening system (bolts and nuts) with a chemical bonding system (adhesive). The adhesive is applied to the coupling surfaces of module cases and cured to form a strong bond, eliminating the need for mechanical fasteners. This substitution reduces assembly time and complexity while maintaining coupling strength.
Solution Approach 2:
The patent combines multiple functions into the adhesive material: it provides both the coupling force (replacing bolts) and the sealing function (preventing moisture ingress). The adhesive serves as both the fastening mechanism and the protective barrier, reducing the total number of components needed.
2Strength
If bolts and nuts are used to couple module cases, then coupling force is sufficient, but material cost increases
Solution Approach 1:
The patent replaces expensive mechanical fasteners (bolts and nuts made of metal) with a more cost-effective adhesive material. The adhesive provides sufficient coupling force while being cheaper in material cost and eliminating the need for multiple fastener components.
Solution Approach 2:
The patent extracts and eliminates the fastener components (bolts, nuts, washers) from the assembly system, retaining only the essential coupling function through adhesive bonding. This reduction in component count directly reduces material cost and simplifies the bill of materials.
3Strength
If multiple fastening components are used, then coupling strength is sufficient, but device complexity increases
Solution Approach 1:
The patent merges the fastening function and sealing function into a single adhesive material. Instead of using separate bolts for fastening and gaskets for sealing, the adhesive performs both functions simultaneously, reducing component count and assembly complexity.
Solution Approach 2:
The patent replaces the complex mechanical fastening system (requiring alignment, threading, and multiple components) with a simpler adhesive application process. The adhesive can be applied in a continuous bead and cured to provide both mechanical strength and environmental sealing.
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 achieves stable fixation, reduces material cost, and simplifies the manufacturing process, thereby increasing durability and efficiency.
Implementation Method 1
a first adhesive interposed between the coupling portion of one module case and the coupling portion of another module case that make male-and-female coupling with each other
Data Source
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AI summary
Disclosed is a battery module having an appropriate coupling force between internal components, reduced production cost and improved manufacture efficiency. The battery module includes a plurality of battery cells; at least two module cases respectively configured to have an inner space for accommodating the plurality of battery cells therein and to have coupling portions protruding toward each other, the at least two module cases being configured such that the coupling portion of one module case makes male-and-female coupling with the coupling portion of another module case; and a first adhesive interposed between the coupling portion of one module case and the coupling portion of another module case that make male-and-female coupling with each other.