Thermoplastic Battery Packaging Sheet for Easy Pack Disassembly
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Solution Overview
Problem
Current power battery packaging designs for new energy vehicles face challenges with low volumetric efficiency, high weight, complex manufacturing processes, and difficulty in disassembly due to strong adhesive bonds, which limit the replacement of faulty battery cells.
Innovation Solution
A packaging sheet with a functional layer made of a thermoplastic polymer having a glass transition temperature between 40° C. and 67° C. and a number-average molecular weight of 10000 to 23000, which provides strong adhesion at room temperature and becomes soft for easy disassembly when heated, allowing for the separation of the heat-conducting structural adhesive layer from the cooling plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If heat-conducting structural adhesive is used to fix battery modules onto cooling plate, then weight is reduced and volumetric efficiency is increased to more than 60%, but the battery pack becomes difficult to disassemble
Solution Approach 1:
The patent changes the physical and chemical parameters of the adhesive by specifying a glass transition temperature of 40-67°C and number-average molecular weight of 10000-23000. This creates a temperature-dependent adhesive that transitions from a rigid bonded state during operation to a soft, easily separable state during disassembly, resolving the contradiction between strong bonding and easy disassembly
Solution Approach 2:
The adhesive's properties are made dynamic through its glass transition behavior. At normal operating temperatures, the adhesive maintains high bonding strength, but when heated above its glass transition temperature during disassembly, it becomes soft and loses adhesion, allowing easy separation. This dynamic property resolution enables both strong fixation and easy disassembly
2Strength
If cross beams and fasteners are used to fix battery modules, then structural strength is improved, but volumetric efficiency decreases to at most 40% and device complexity increases
Solution Approach 1:
The patent replaces the mechanical fastening system (cross beams and fasteners) with a chemical bonding system using heat-conducting structural adhesive. This substitution eliminates the need for complex mechanical structures, increases volumetric efficiency from 40% to over 60%, while maintaining structural strength through the adhesive bond
Solution Approach 2:
The patent merges multiple functions into the adhesive material: structural bonding, heat conduction, and shock absorption. This consolidation eliminates the need for separate cross beams and fasteners, simplifying the structure and increasing volumetric efficiency while maintaining or improving structural strength
3Strength
If cross beams and fasteners are used to fix battery modules, then structural strength is improved, but device complexity and manufacturing complexity increase
Solution Approach 1:
The patent replaces the complex mechanical system of cross beams and fasteners with a simple adhesive bonding system. This substitution dramatically reduces device complexity while maintaining structural strength through the heat-conducting structural adhesive
Solution Approach 2:
The patent combines multiple structural components (cross beams, fasteners, and adhesive layers) into a single integrated adhesive bonding system. This merging simplifies the overall device structure, reduces the number of parts, and streamlines manufacturing processes
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
The solution results in a power battery assembly that is simple in structure, lightweight, and high in battery volume ratio, facilitating easy disassembly and improving the efficiency of updating and repairing power batteries.
Implementation Method 1
the thermoplastic polymer has a glass transition temperature in a range of 40° C. to 67° C.
Implementation Method 2
a heat-conducting structural adhesive layer in contact with the battery module
Data Source
AI summary
The present invention provides a packaging sheet for a power battery of a new energy vehicle, a power battery assembly of a new energy vehicle, and a method for disassembling the power battery assembly of a new energy vehicle. The packaging sheet comprises a functional layer, the functional layer comprises a thermoplastic polymer, and the thermoplastic polymer has a glass transition temperature in a range of 40° C. to 67° C. and a number-average molecular weight in a range of 10000 to 23000. According to the present invention, the packaging sheet for packaging a power battery of a new energy vehicle is simple in structure and easy to disassemble, and the obtained power battery assembly of a new energy vehicle is simple in structure, light in weight and high in battery volume ratio, and in particular, can be disassembled through a very simple process, thereby greatly improving the efficiency of updating and repairing new energy vehicle power batteries for electric vehicles.