Traction Battery Pack Assembly for Replaceable Bonded Cell Stacks
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Solution Overview
Problem
Existing methods for assembling traction battery packs lack efficiency in electrically connecting and bonding cell stacks without the need to rupture bonds, making it difficult to replace cells without damaging the assembly.
Innovation Solution
A method involving the compression of cell stacks within an enclosure structure, followed by electrical connection using busbars, and subsequent adhesive bonding, allowing for electrical inspection and potential cell replacement before forming permanent bonds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cell stacks are bonded together immediately after insertion, then assembly speed is improved, but cell replacement becomes difficult without damaging bonds
Solution Approach 1:
The patent applies preliminary action by performing electrical connections and inspections before bonding the cell stacks. The method sequence is: insert cell stacks → electrically connect → inspect → replace if needed → bond. This allows cells to be replaced before permanent bonding occurs, resolving the contradiction between assembly speed and ease of repair.
2Strength
If compression force is applied continuously during assembly, then structural integrity is improved, but electrical connection quality deteriorates due to cell deformation
Solution Approach 1:
The patent applies dynamics by controlling the compression force to be applied at specific stages: compression is applied during insertion to maintain structural integrity, then maintained at a controlled level during electrical connection to prevent deformation, and finally increased after bonding to ensure long-term stability. This dynamic control resolves the contradiction between structural integrity and electrical connection quality.
3Stability of the object's composition
If adhesive bonding is used to secure cell stacks, then structural stability is improved, but manufacturing complexity increases due to additional bonding steps
Solution Approach 1:
The patent merges multiple functions into the bonding step: the adhesive bonding simultaneously secures the cell stacks mechanically, provides thermal management interface, and creates a permanent structural connection. This consolidation achieves structural stability while managing the complexity by combining multiple requirements into a single process step.
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 traction battery packs with the ability to replace cells without damaging the bond between them, ensuring reliable and efficient electrical connections while maintaining structural integrity.
Implementation Method 1
inserting a plurality of cell stacks into an enclosure structure that compresses the plurality of cell stacks
Implementation Method 2
bonding the plurality of cell stacks after electrically connecting the plurality of cells stacks
Data Source
AI summary
A battery pack assembly method includes inserting a plurality of cell stacks into an enclosure structure that compresses the plurality of cell stacks. The method further includes electrically connecting the plurality of cells stacks together and bonding the plurality of cell stacks after electrically connecting the plurality of cells stacks.