Battery Module Cell Insertion Using Ultrasonic Vibration
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Solution Overview
Problem
The insertion of cylindrical battery cells into battery module housings often requires repeated pressing, leading to increased production time and potential mechanical damage due to the cells springing back after the pressing force is reduced, and using higher forces to prevent this can further damage the cells.
Innovation Solution
The method involves using high-frequency vibrations, generated by an ultrasonic generator, to reduce the frictional force required for inserting battery cells, allowing for precise placement with lower pressing force and incorporating a cooling medium within the module housing for effective cooling, while maintaining mechanical stability and preventing electrical and mechanical damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a larger pressing force is used to insert round cells into the battery module housing, then the mechanical stability of the battery module is improved, but the battery cells may be mechanically damaged
Solution Approach 1:
The patent applies mechanical vibrations during the insertion process to reduce friction between the round cells and the housing. The vibrations cause the cells to oscillate, allowing them to be pressed into place with lower force while maintaining stable positioning, thus preventing mechanical damage to the cells.
2Manufacturing precision
If repeated pressing is used to insert battery cells into the housing, then the insertion completeness is improved, but the production time is lengthened
Solution Approach 1:
By introducing vibrations during insertion, the patent enables complete and stable cell placement in a single operation. The vibrations help the cells settle into their final positions without springing back, eliminating the need for repeated pressing cycles and thereby reducing production time.
3Stability of the object's composition
If a larger pressing force is used to prevent spring back of battery cells, then the positional stability of cells is improved, but the risk of mechanical damage increases
Solution Approach 1:
The vibrations during insertion reduce friction and allow the cells to be pressed firmly into position with lower force. This combination of vibration and reduced pressing force achieves both positional stability and prevention of mechanical damage.
Solution Approach 2:
The patent changes the physical state or conditions during insertion by introducing vibrational motion. This parameter change allows the insertion process to achieve stable positioning without requiring high pressing forces that would cause damage.
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 enables efficient and precise insertion of battery cells with reduced mechanical stress, improved stability, and rapid cooling, suitable for use in electric vehicles and hybrid systems.
Implementation Method 1
high-frequency vibrations in particular can be used in order to reduce the frictional force along the at least one battery cell
Implementation Method 2
The vibrations are preferably generated by means of an ultrasonic generator
Implementation Method 3
The battery module housing is preferably filled with a cooling medium. In this way, the battery module housing acts not only as a mechanical holder for the battery cells contained therein, but also as a cooling housing for the same. The affected battery cells are thus cooled directly by the cooling medium in the battery module housing.
Data Source
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AI summary
The invention relates to a method (30, 40) for manufacturing a battery module (116, 216), a device (10, 20) for carrying out this method, and the use of such a method. The method (30, 40) for manufacturing a battery module (116, 216) comprising at least one battery cell (108) and a battery module housing (112, 212) is characterized in that the at least one battery cell (108) is inserted into the battery module housing (112, 212) by means of pressing and applying vibrations.