Battery Module Adhesive Gap Filling via Porous Layer
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Solution Overview
Problem
The existing methods for manufacturing battery modules face inefficiencies in filling the gap between the battery retention section of a holder and the battery cell with adhesive, leading to poor adhesion strength due to high viscosity adhesives and difficulty in uniform spreading, resulting in inferior working efficiency and adhesion quality.
Innovation Solution
A method involving the formation of a deformable porous layer on the battery cell's outer surface, impregnated with adhesive, which is then inserted into the holder's retention section, allowing the adhesive to fill the gap effectively by deformation of the porous layer and fluidity of the adhesive, ensuring complete coverage and strong adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive is injected into gaps between battery retention sections and battery cells (potting method), then adhesion strength is improved, but manufacturing time increases and working efficiency deteriorates
Solution Approach 1:
The adhesive is applied to the outer circumferential surface of the battery cell before insertion into the holder, rather than injecting after positioning. This preliminary application allows the adhesive to be ready for immediate bonding upon insertion, eliminating the time-consuming injection and solidification processes while ensuring proper adhesion coverage.
2Stability of the object's composition
If gap between battery retention section and battery cell is reduced for stable holding, then positioning stability is improved, but adhesive spreading becomes difficult due to high viscosity and frictional resistance
Solution Approach 1:
The adhesive is applied in a liquid state with lower viscosity to the outer circumferential surface of the battery cell, allowing easy spreading and penetration into the narrow gap. After insertion, the adhesive solidifies to provide strong bonding. This parameter change from liquid to solid state enables both easy application and strong adhesion in the constrained space.
3Productivity
If adhesive is applied on outer circumferential surface of battery cell for faster manufacturing, then working efficiency is improved, but uniform spreading throughout narrow gap becomes difficult due to high viscosity
Solution Approach 1:
A porous layer is introduced as an intermediary between the adhesive and the battery cell surface. This porous layer facilitates uniform distribution of the adhesive throughout the narrow gap by capillary action, ensuring complete coverage and eliminating air pockets while maintaining the efficiency benefits of pre-application.
4Productivity
If adhesive does not spread uniformly throughout gap, then air becomes trapped in adhesion layer, but adhesion area and strength deteriorate
Solution Approach 1:
A porous layer is used to enable complete penetration and uniform distribution of adhesive throughout the narrow gap. The porous structure allows the adhesive to flow through and displace air effectively, ensuring full coverage and eliminating trapped air pockets that would compromise adhesion quality, while maintaining the manufacturing efficiency of the pre-application method.
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 ensures that the gap between the holder and the battery cell is adequately filled with adhesive, enhancing the adhesion strength and manufacturing efficiency by utilizing the deformable porous layer and fluid adhesive to spread uniformly and fill the narrow spaces without leaving gaps.
Implementation Method 1
a deformable porous layer is formed on the outer circumferential surface of the battery cell and the porous layer is impregnated with an adhesive to form an adhesion layer including the porous layer and the adhesive
Data Source
AI summary
In a battery module in which battery cells are inserted and adhered to battery retention sections each having a hole and formed on a holder, an objective is to provide a technology for sufficiently filling the gap between the battery retention section of the holder and the battery cell with an adhesive. A deformable porous layer 40 is formed on an outer circumferential surface 11 of each battery cell 1, and an adhesion layer 4 is formed by impregnating the porous layer 40 with an adhesive. Alternatively, the deformable porous layer 40 is formed on the outer circumferential surface 11 of each of the battery cells 1, and an adhesive layer 46 including an adhesive is formed on the back side in an insertion direction with respect to the porous layer 40.