Battery Module Assembly With Pre-Compression for Easier Mounting
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Solution Overview
Problem
The compression of battery cells during the mounting procedure in existing battery devices for electric aircraft is difficult and complex, requiring precise application of force while integrating the cells into compartments, which complicates the manufacturing process.
Innovation Solution
The method involves separately constructing the battery housing with compartments and stacking battery cells to form modules outside the housing, allowing for independent compression and insertion of the modules into the housing, using tools like vacuum bags or pliers to apply compression forces, and filling spaces with compression material to maintain the force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery cells are stacked and compressed within the compartment during mounting, then the battery module achieves proper compression for full functionality, but the mounting procedure becomes difficult and complex due to the need to hold compression force while completing compartment walls
Solution Approach 1:
The mounting process is divided into separate steps: first the battery module is compressed independently using a compression device, then the compartment is constructed around the already-compressed module. This segmentation separates the compression operation from the compartment assembly, eliminating the need to maintain compression force during wall installation.
Solution Approach 2:
The battery module is compressed in advance before being installed into the compartment. By performing the compression action preliminarily, the module is prepared in its final compressed state before mounting, so no further compression is needed during compartment assembly.
2Manufacturing precision
If battery cells are compressed during the mounting procedure, then the battery module achieves proper compression, but the process requires simultaneous manipulation of compression force application and compartment wall installation
Solution Approach 1:
The manufacturing process is segmented into distinct operations: compression of the battery module using a dedicated compression device, followed by separate compartment assembly. This allows each operation to be optimized independently without the constraints of simultaneous execution.
Solution Approach 2:
A compression device acts as an intermediary tool to apply the required compression force to the battery module before mounting. This intermediary device handles the compression task separately, allowing the mounting process to focus solely on installing the pre-compressed module into the compartment.
3Force
If compartment walls are used to provide compression force to battery cells, then the cells are compressed, but the compression force cannot be held while completing the compartment walls
Solution Approach 1:
The compression force is applied in advance using a separate compression device before the compartment walls are installed. The battery module is compressed to its final state preliminarily, eliminating the need to maintain compression force during the subsequent wall installation process.
Solution Approach 2:
The compression function is extracted from the compartment structure itself. Instead of relying on the compartment walls to provide and maintain compression force, a dedicated compression device is used to apply the force separately before mounting, and the compressed module is then installed as a complete unit.
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 simplifies the manufacturing process by decoupling the cell stacking and housing assembly, enabling easier handling and secure compression without requiring simultaneous manipulation of both, thus reducing complexity and enhancing safety.
Implementation Method 1
stacked battery cells in form of the battery module are then inserted in the finalised battery housing through the receiving opening
Data Source
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AI summary
The invention is related to a Method for producing a battery device (10), in particular for use in an electric aircraft, comprising the following steps: - Providing a battery housing (20) with at least one cell compartment (30) having one receiving opening (32) and surrounding compartment walls (34) for holding a battery module (40) with multiple battery cells (42), - Stacking multiple battery cells (42) on top of each other to create at least one battery module (40), - Inserting the at least one battery module (40) into the at least one cell compartment (30) through the receiving opening (32), - Closing the receiving opening (32) of the at least one cell compartment (30).