Battery Module End Plate Buffers for Adhesive Overflow Control
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Solution Overview
Problem
Existing rechargeable battery modules face challenges in maintaining structural integrity and adhesive application efficiency due to adhesive overflow and non-uniform adhesion, particularly at the edges and corners of stacked unit cells.
Innovation Solution
Incorporation of adhesive accommodation buffers with grooves at the edges of end cell covers and end plates to manage adhesive overflow, ensuring uniform adhesion and enhanced structural stability by accommodating excess adhesive.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive is applied to bond the end plate and side plate to unit cells, then structural integrity is improved, but adhesive overflow occurs causing non-uniform adhesion and manufacturing defects
Solution Approach 1:
The end plate and side plate are designed with adhesive accommodation buffers at specific locations (edges and corners) where adhesive overflow is most likely to occur. These buffers provide localized adhesive capacity exactly where needed, allowing uniform adhesion across the entire bonding interface while preventing overflow defects at critical locations.
Solution Approach 2:
The adhesive accommodation buffers are pre-formed as integral parts of the end plate and side plate structures before assembly. This preliminary preparation ensures that when adhesive is applied during assembly, the buffers are already in position to capture and accommodate excess adhesive, preventing overflow before it can cause manufacturing defects.
2Strength
If adhesive is applied generously to ensure complete coverage, then adhesion strength is improved, but adhesive overflow causes structural defects and reduced reliability
Solution Approach 1:
The adhesive accommodation buffers convert the harmful effect of adhesive overflow into a beneficial feature. By providing dedicated spaces within the buffer structures to hold excess adhesive, the design allows generous adhesive application to ensure complete coverage and strong bonding, while the overflow is captured and contained rather than causing defects that would reduce structural reliability.
3Manufacturing precision
If adhesive buffers are added to manage overflow, then adhesion uniformity is improved, but device complexity increases
Solution Approach 1:
The adhesive accommodation buffers are merged with the end plate and side plate structures, forming integrated components rather than separate additions. The buffers are formed as integral parts of the plates themselves, combining the structural function of the plates with the adhesive management function of the buffers, thereby improving adhesion uniformity without significantly increasing overall device complexity.
Data Source
AI summary
A rechargeable battery module includes a plurality of unit cells that are stacked in a first direction and electrically connected with each other; an end cell cover that is adjacent to an outermost unit cell in the first direction among the plurality of unit cells, the end cell cover including at least one adhesive accommodation buffer adjacent to an edge thereof; an end plate at an outer side of the end cell cover and configured to support the plurality of unit cells by pressing the plurality of unit cells in the first direction; and a side plate that extends in the first direction and is configured to support a side surface of the plurality of unit cells.