Battery Module Adhesive Layer Design for Uniform Filling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for manufacturing battery modules face inefficiencies in adhesive application and solidification, leading to incomplete filling of the adhesive layer between the battery cell and the holder, which affects the adhering strength and stability of the battery cell retention.
Innovation Solution
A method involving the use of different viscosity adhesives applied to both the inner circumferential surface of the holder and the outer circumferential surface of the battery cell, with the high viscosity adhesive forming a cell-side layer and the low viscosity adhesive forming a holder-side layer, ensuring complete filling and contact along the entire circumference, and allowing for deformation to fill gaps effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the adhesive is coated to the outer circumferential surfaces of the battery cells and the battery cells are inserted into the battery retaining section, then the work efficiency is improved, but the adhesive cannot be uniformly spread in the narrow gap between the inner circumferential surface of the battery retaining section and the outer circumferential surface of the battery cell
Solution Approach 1:
The patent changes the viscosity parameter of the adhesive by using two different types of adhesives: a first adhesive with higher viscosity and a second adhesive with lower viscosity. The lower viscosity adhesive can flow more easily to fill the narrow gap uniformly, while the higher viscosity adhesive provides stronger bonding. This parameter change resolves the contradiction between work efficiency and coating uniformity.
Solution Approach 2:
The patent uses a composite adhesive system consisting of two different adhesives with different viscosities. The first adhesive (higher viscosity) is applied to the battery cell outer surface, and the second adhesive (lower viscosity) is applied to the battery retaining section inner surface. This composite approach combines the advantages of both adhesives: the higher viscosity adhesive provides strong adhesion to the battery cell, while the lower viscosity adhesive ensures uniform filling of the narrow gap.
2Reliability
If the gap between the inner circumferential surface of the battery retaining section and the outer circumferential surface of the battery cell is kept small to stably retain the battery cell, then the retention stability is improved, but the adhesive cannot be sufficiently spread due to high friction resistance
Solution Approach 1:
The patent addresses the high friction resistance issue by changing the viscosity parameter of the adhesive. The second adhesive with lower viscosity has reduced internal friction and can flow more easily through the narrow gap, overcoming the friction resistance between the adhesive and the inner circumferential surface of the battery retaining section. This enables sufficient adhesive spreading while maintaining the small gap for stable retention.
Solution Approach 2:
The patent introduces the second adhesive with lower viscosity as an intermediary substance that facilitates the bonding process. This intermediary adhesive with optimized viscosity characteristics acts as a mediator between the battery cell and the battery retaining section, enabling effective filling of the narrow gap and reducing the harmful effect of friction resistance.
3Object-generated harmful factors
If the adhesive is not sufficiently spread in the gap between the inner circumferential surface of the battery retaining section and the outer circumferential surface of the battery cell, then air is caught inside the adhesive layer, but the adhering strength is reduced
Solution Approach 1:
The patent changes the viscosity parameter of the adhesive to eliminate air entrapment. The second adhesive with lower viscosity can flow more easily and completely fill the narrow gap, displacing air effectively. This ensures sufficient adhesive spreading without air pockets, thereby achieving both the elimination of harmful air entrapment and the maintenance of high adhering strength.
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 approach ensures a robust and uniform adhesive layer, enhancing the adhering strength and stability of the battery cell to the holder, improving work efficiency and preventing air entrapment, thereby improving the overall performance of the battery module.
Implementation Method 1
the adhesive has a relatively high viscosity, a friction resistance with the inner circumferential surface of the battery retaining section is relatively large
Implementation Method 2
allowing for deformation to fill gaps effectively
Implementation Method 3
an adhesive is injected between an inner circumferential surface of the battery retaining section of the holder and outer circumferential surface of the battery cell, and the adhesive is solidified to form an adhesive layer
Data Source
AI summary
A technique for sufficiently filling an adhesive between a battery retaining section of a holder and a battery cell in a battery module configured by the battery cell being inserted and adhered in the aperture-shaped battery retaining section provided in the holder is provided. An adhesive layer that adheres a holder and a battery cells in a battery module is formed in a two-layer structure of a holder-side adhesive layer making contact with an inner circumferential surfaces of a battery retaining sections and a cell-side adhesive layer making contact with an outer circumferential surfaces of the battery cells, and different types of adhesives are used for an adhesive configuring the holder-side adhesive layer and an adhesive configuring the cell-side adhesive layer.