Battery Module Adhesive Fixing via Phase Transition
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Solution Overview
Problem
Existing methods for manufacturing battery modules fail to securely fix cylindrical battery cells within a housing, leading to potential damage and disconnection issues due to adhesive flow and uneven distribution, which affects durability and manufacturing efficiency.
Innovation Solution
A method involving a thermally and ultraviolet-curable adhesive is applied to the inner surface of the module housing, partially cured to increase viscosity, then lowered to facilitate cell insertion, and finally fully cured using a combination of heat and UV radiation to ensure uniform adhesion and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive is applied to the inner surface of the housing to fix secondary batteries, then the batteries can be secured against movement, but the adhesive flows down from the inner surface causing loss of uniform distribution and constant thickness
Solution Approach 1:
The patent changes the physical state parameter of the adhesive by introducing a phase transition mechanism. The adhesive is applied in a liquid state, then heated to transition to a gel state for positioning, and finally cured to achieve complete fixation. This parameter change resolves the contradiction by allowing the adhesive to be applied without immediate flow, then fixed in the desired position.
Solution Approach 2:
The patent applies preliminary heating to transform the adhesive from liquid to gel state before the batteries are fully positioned. This preliminary action allows the adhesive to maintain its shape and position on the housing surface, preventing flow down and enabling uniform distribution before final curing occurs.
2Reliability
If adhesive is applied to fix secondary batteries in the housing, then the batteries are secured, but the adhesive is lost out of the housing causing contamination
Solution Approach 1:
The patent uses phase transition (liquid to gel to solid) to control adhesive behavior. The gel state provides sufficient viscosity to prevent adhesive from flowing out of the housing during battery positioning, while the subsequent curing process ensures complete fixation. This eliminates contamination while maintaining fixing reliability.
3Reliability
If adhesive is applied to secure secondary batteries, then movement is prevented, but the adhesive cannot maintain uniform distribution and constant thickness
Solution Approach 1:
The patent applies preliminary heating to transform adhesive to gel state before battery installation. This gel state maintains the adhesive in place with uniform thickness, preventing both flow down and premature curing. The adhesive remains in this controlled state during battery positioning, ensuring consistent thickness throughout the bonding area.
Solution Approach 2:
The patent employs a multi-stage process with distinct phases: liquid application, gel transformation, battery positioning, and final curing. Each stage is sequentially controlled to maintain adhesive properties appropriate for that phase, ensuring uniform distribution and constant thickness throughout the process.
4Ease of manufacture
If adhesive is used to fix secondary batteries without movement prevention, then the fixing process is simple, but the batteries move inside the accommodation space causing damage
Solution Approach 1:
The patent uses phase transition of the adhesive (liquid→gel→solid) to provide progressive fixation. The gel state allows easy battery insertion while preventing movement, and the final cured state provides strong mechanical protection. This maintains manufacturing simplicity while ensuring battery protection through the physical properties of the adhesive.
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 prevents adhesive flow and ensures uniform distribution, enhancing manufacturing efficiency, reducing contamination risks, and improving the durability of the battery module by securely fixing cells even under conditions of frequent shaking or impact.
Implementation Method 1
partially curing the added adhesive by applying heat thereto to increase viscosity of the adhesive
Implementation Method 2
finally curing the adhesive by irradiating ultraviolet rays to the adhesive whose viscosity is lowered in the step (e)
Data Source
AI summary
A method for manufacturing a battery module includes preparing a plurality of cylindrical battery cells having electrode terminals respectively at upper and lower portions, and a module housing having an accommodation portion with a plurality of hollow structures to accommodate the cylindrical battery cells therein; adding an adhesive having thermally and ultraviolet curing properties to an inner surface of the accommodation portion; partially curing the adhesive by applying heat thereto to increase a viscosity of the adhesive; accommodating the cylindrical battery cells in the accommodation portion so that the partially-cured adhesive is between the accommodation portion of the module housing and the cylindrical battery cells; after the accommodating of the cylindrical battery cells in the accommodation portion, applying heat to the adhesive to lower the viscosity of the adhesive; and, after the viscosity is lowered by applying the heat, curing the adhesive by irradiating ultraviolet rays to the adhesive.