Battery Module Cell Frame for Fast Photocurable Cell Fixation
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Solution Overview
Problem
The existing battery modules face challenges in reducing process time due to the lack of efficient fixing means for battery cells within the housing, leading to potential damage and connection issues during vibrations and shocks in mobile devices and vehicles.
Innovation Solution
A battery module design incorporating a light-transmitting cell frame with a photocurable resin adhesive layer, where the cell frame has total internal reflection properties and a diffuse reflection member to enhance light efficiency and photocuring, allowing for faster adhesive curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a photocurable resin adhesive layer is used to fix battery cells, then the fixation reliability is improved, but the process time is increased due to the curing time required
Solution Approach 1:
The adhesive layer is applied in advance to the cell frame or battery cells before assembly, allowing the adhesive to be in position and ready for immediate curing. This preliminary application ensures proper positioning and coverage, while the curing process can occur during or after assembly without delaying production
Solution Approach 2:
The patent replaces traditional thermal curing methods with photocuring technology. Instead of using heat and long curing cycles, ultraviolet light is used to initiate rapid polymerization of the photocurable resin. This substitution reduces curing time from hours to minutes or even seconds, dramatically improving production efficiency while maintaining strong adhesive bonds
2Device complexity
If battery cells are accommodated without fixing means in the housing, then the device complexity is reduced, but the reliability deteriorates due to movement and damage during vibrations and shocks
Solution Approach 1:
The patent combines the fixing function with the existing cell frame structure. The adhesive layer is integrated into the assembly process, bonding the battery cells directly to the cell frame which is already part of the housing structure. This merging approach provides secure fixation without requiring separate mechanical fasteners, clips, or additional fixing components, thus maintaining low device complexity while achieving high reliability
Solution Approach 2:
The adhesive layer serves as an intermediary substance between the battery cells and the cell frame. This intermediary material creates a strong chemical bond that prevents relative movement between components during vibration and shock, while being simple to apply and cure. The adhesive acts as a bonding mediator that transfers and distributes mechanical stresses, protecting both the battery cells and connection points
3Productivity
If a light-transmitting cell frame with total internal reflection is used, then the photocuring efficiency is improved, but the manufacturing complexity is increased
Solution Approach 1:
The patent changes the optical parameters of the cell frame material by selecting resins with specific refractive indices and light transmission properties. The cell frame is made from transparent or translucent resin materials that allow ultraviolet light to pass through and reflect internally. This parameter change enables the existing cell frame structure to serve dual purposes: mechanical support and light guidance for photocuring, without requiring additional complex manufacturing processes
Solution Approach 2:
The cell frame is designed to perform multiple functions simultaneously: it provides mechanical support for the battery cells, serves as a structural component of the housing, and acts as a light guide for photocuring the adhesive layer. By making the cell frame itself light-transmitting with total internal reflection properties, the patent eliminates the need for separate curing channels or light guides, reducing overall device complexity while maximizing photocuring efficiency
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 solution significantly reduces the process time by using a photocurable resin adhesive layer that can be efficiently cured through light transmission and reflection, ensuring secure fixation of battery cells within the module.
Implementation Method 1
an adhesive layer located between the bottom plate and the plurality of battery cells, wherein the adhesive layer is formed of a photocurable resin
Implementation Method 2
the cell frame may be formed of a resin that generates total internal reflection into the cell frame
Data Source
AI summary
A battery module according to one or more example embodiments includes a bottom plate, a cell frame located on the bottom plate, a plurality of battery cells mounted to the cell frame, and an adhesive layer located between the bottom plate and the plurality of battery cells. The cell frame has light transmittance. A battery pack including the battery module is also disclosed.