Battery Module Thermoplastic Bonding With Laser-Absorbing Insert
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Solution Overview
Problem
Existing methods for bonding thermoplastic components in lithium ion battery modules are inefficient, as they require solvents, adhesives, or high power ultrasonic energy, and lack precision, making them unsuitable for high-performance applications like electric vehicles.
Innovation Solution
A method involving an energy absorbing insert positioned between thermoplastic layers, where energy, such as laser energy, is applied to melt and fuse the layers, creating a precise and efficient weld joint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If solvents or adhesives are used for bonding thermoplastic components, then bonding is achieved, but the process becomes inefficient and less precise
Solution Approach 1:
The patent replaces mechanical bonding methods (solvents, adhesives) with laser-based energy absorption and melting. The laser energy is absorbed by the thermoplastic material to melt and fuse components together, eliminating the need for chemical bonding agents and improving both precision and efficiency
Solution Approach 2:
The patent utilizes phase transition of thermoplastic materials from solid to molten state through laser heating. The controlled melting and subsequent cooling creates precise weld joints without requiring solvents or adhesives, thereby improving bonding precision and process efficiency
2Strength
If high power ultrasonic energy is used for bonding, then bonding is achieved, but the process lacks precision and is unsuitable for high-performance applications
Solution Approach 1:
The patent applies laser energy locally to specific bonding zones rather than using diffuse ultrasonic energy. The laser can be precisely positioned and focused on the exact area requiring bonding, creating strong weld joints with high precision suitable for high-performance applications
Solution Approach 2:
The patent replaces ultrasonic vibration-based bonding with laser-based thermal bonding. This substitution enables precise control of energy delivery to the bonding interface, achieving both high weld joint strength and high bonding precision
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 allows for precise and efficient bonding of thermoplastic components in lithium ion battery modules, enhancing their sealing and performance in high-voltage energy storage applications, such as electric vehicles, by creating a strong and precise weld joint.
Implementation Method 1
Energy is applied to the energy absorbing insert to melt the energy absorbing insert and thereby fuse the first thermoplastic layer to the second thermoplastic layer
Implementation Method 2
Energy is applied to the energy absorbing insert to melt the energy absorbing insert
Implementation Method 3
the first thermoplastic layer is a transmissive or semi-transmissive layer configured to allow the energy the pass through the first thermoplastic layer for absorption by the energy absorbing insert
Data Source
AI summary
A method for bonding components of a lithium ion battery module includes positioning an energy absorbing insert adjacent to a first thermoplastic layer of the lithium ion battery module and to a second thermoplastic layer of the lithium ion battery module. Energy is applied to the energy absorbing insert to melt the energy absorbing insert and thereby fuse the first thermoplastic layer to the second thermoplastic layer. The first thermoplastic layer is a transmissive or semi-transmissive layer configured to allow the energy the pass through the first thermoplastic layer for absorption by the energy absorbing insert.