Battery Module Guide Rails and Adhesive Bonding
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Solution Overview
Problem
Battery cell stacks in traction battery modules for electric vehicles are prone to damage due to relative movements between the stack and the module housing, leading to potential failures, short-circuits, or exothermic reactions caused by vibrations and rapid accelerations.
Innovation Solution
A battery module design featuring guide rails and a curing adhesive that forms a form-fitting unit to securely fix the battery cell stack within the module housing, preventing relative movements and adapting to varying clearance gaps, ensuring a secure bond regardless of tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If clearance is provided between the battery cell stack and the module housing for easier insertion, then ease of assembly is improved, but relative movements and vibrations during operation cause damage to the battery cell stack
Solution Approach 1:
The adhesive is applied to the module housing before the battery cell stack is inserted, allowing the bonding action to occur after insertion while maintaining the clearance for easy assembly. The adhesive fills the clearance gap and cures to prevent relative movements during operation.
Solution Approach 2:
The adhesive acts as an intermediary substance between the module housing and the battery cell stack, filling the clearance gap and creating a form-fitting unit that prevents relative movements while allowing the components to remain separated by the clearance during assembly.
2Reliability
If the battery cell stack is tightly fitted in the module housing to prevent relative movements, then reliability is improved, but insertion becomes difficult and requires precise tolerances
Solution Approach 1:
The adhesive is prepared and positioned on the module housing before the battery cell stack is inserted, enabling a tight fit to be achieved after insertion without requiring precise tolerances during the insertion process itself.
Solution Approach 2:
The adhesive changes from a liquid or semi-liquid state during application to a cured solid state after insertion, transforming the clearance gap from a harmful space into a bonding medium that secures the battery cell stack firmly in position.
3Reliability
If adhesive is used to bond the battery cell stack to the module housing, then relative movements are prevented, but the adhesive must adapt to varying clearance gaps due to tolerances
Solution Approach 1:
The adhesive's viscosity and flow characteristics allow it to adapt to varying clearance gaps during application, and its curing process creates a rigid form-fitting unit that prevents relative movements regardless of the initial clearance size.
Solution Approach 2:
The adhesive bonding is applied segmentally along the sides of the battery cell stack where the clearance gaps exist, creating multiple form-fitting connections that collectively prevent relative movements while adapting to local variations in clearance.
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
The solution effectively prevents damage to the battery cell stack by securely bonding it to the module housing, eliminating risks of failure and short-circuits, and ensuring stability across different clearance gap sizes.
Implementation Method 1
the battery cell stack is bonded to the module housing by means of a curing adhesive. The cured adhesive forms a form-fitting unit that fixes the battery cell stack in the module housing
Data Source
AI summary
A battery module for a traction battery of a battery electric vehicle and a method for manufacturing a battery module are disclosed. The battery module includes a cohesive battery cell stack and a module housing. A guide unit with at least two guide rails are provided on two opposite sides of the battery module. The battery cell stack is inserted into the module housing in a direction of insertion via the at least two guide rails and held transversely to the direction of insertion. The battery cell stack is bonded to the module housing via a cured adhesive. The cured adhesive defines a form-fitting unit that holds the battery cell stack in the module housing in at least one of a form-fitting and force-fitting manner.