Battery Module Assembly Using Light-Cure Adhesive
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Solution Overview
Problem
Assembling high-voltage, large-format battery modules with cylindrical cells requires additional machinery or manufacturing time to maintain the position of each cell when using a single carrier layer, which is undesirable.
Innovation Solution
A method involving a carrier layer with recesses and light-cure adhesive is used, where the adhesive is partially cured while the carrier layer is in a first orientation, securing the cells before reorienting it for full curing, thus maintaining cell position without additional machinery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a single carrier layer is used at one end of the battery cells, then the battery module size and thickness are reduced, but additional machinery or manufacturing time is required to maintain battery cell positions during assembly
Solution Approach 1:
The adhesive is applied to the carrier layer before the battery cells are inserted, and the carrier layer is partially cured in a first orientation to preliminarily secure the cells. This preliminary action allows the cells to be positioned without requiring additional machinery to maintain their positions during subsequent assembly steps.
Solution Approach 2:
The carrier layer is designed to be reconfigurable between different orientations. It is initially positioned in a first orientation for partial curing of the adhesive, then repositioned in a second orientation for complete curing. This dynamic repositioning allows the same carrier layer to perform multiple functions without requiring additional fixed machinery.
2Length of stationary object
If a single carrier layer is used at one end of the battery cells, then the battery module thickness is reduced, but manufacturing time increases due to additional steps to maintain cell position
Solution Approach 1:
The adhesive is preliminarily cured in the first orientation before the battery module is flipped to the second orientation. This preliminary curing establishes cell positions early in the process, eliminating the need for time-consuming machinery interventions later to maintain positions during subsequent assembly steps.
Solution Approach 2:
The curing process is divided into two periodic stages: partial curing in the first orientation followed by complete curing in the second orientation. This periodic action allows the adhesive to set in stages, maintaining cell positions without requiring continuous mechanical support or additional time-consuming interventions.
3Manufacturing precision
If additional machinery is used to maintain battery cell positions during assembly, then cell positioning accuracy is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The mechanical system of additional positioning machinery is replaced with a chemical system using light-cure adhesive. The adhesive, when cured, provides the necessary mechanical constraint to maintain battery cell positions, eliminating the need for complex mechanical positioning devices while achieving the same positioning accuracy.
Solution Approach 2:
The light-cure adhesive acts as an intermediary between the carrier layer and the battery cells. It mediates the connection by bonding the cells to the carrier layer, providing stable positioning without requiring direct mechanical intervention or complex positioning machinery during the assembly process.
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
Enables efficient assembly of battery modules with a single carrier layer without the need for complex machinery, ensuring accurate positioning and secure adhesion of battery cells during the assembly process.
Implementation Method 1
selectively applying a light-cure adhesive to a sidewall of each of the plurality of recesses
Data Source
AI summary
A battery module and a method of assembling a battery module are provided. The method includes selectively applying a light-cure adhesive to recesses in a first side of a carrier layer and inserting battery cells into respective recesses. The method further includes exposing the first side of the carrier layer to light to at least partially cure the light-cure adhesive with the carrier layer in a first orientation, moving the carrier layer into a second orientation, and exposing a second opposite side of the carrier layer to light to fully cure the light-cure adhesive. The recesses may include a sidewall having crush points spaced apart along the sidewall and a bottom portion having an opening between a pair of crush points, where adhesive is not disposed between the pair of crush points.