Battery Cell Stack Adhesive Spraying for Swelling-Tolerant Bonding
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Solution Overview
Problem
Existing methods for manufacturing battery cell stacks face challenges in stability and reliability due to the use of tape-type adhesives, which are cumbersome to apply, generate waste, and lose adhesion as batteries swell, increasing manufacturing costs and reducing effective adhesion area.
Innovation Solution
A method using a solvent-free adhesive resin composition applied via nozzles with controlled application amounts and patterns to enhance adhesion, particularly on non-flat battery cell surfaces, ensuring full contact and improved stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If tape type adhesive is used to attach battery cells, then the manufacturing process becomes simpler, but the effective adhesion area is reduced due to surface deformation from battery swelling
Solution Approach 1:
The patent changes the physical state of the adhesive from a rigid tape form to a viscous resin composition that can flow and adapt. The adhesive resin is applied in a liquid state and then cured to form a strong bond, allowing it to conform to the deformed battery cell surfaces while maintaining adhesion stability.
Solution Approach 2:
The patent uses a composite adhesive system consisting of multiple resin components (first and second resin compositions) with different properties. The first resin provides initial adhesion while the second resin enhances cross-linking and structural stability, creating a composite material that maintains effective adhesion area despite battery swelling.
2Ease of manufacture
If tape type adhesive with uniform thickness is applied, then the application process is simplified, but the adhesive force is not properly expressed due to reduced effective adhesion area
Solution Approach 1:
The patent transitions from a static, uniform-thickness tape adhesive to a dynamic liquid resin composition that can flow and redistribute during the bonding process. This allows the adhesive to dynamically adjust its distribution to maximize contact area and adhesive force while maintaining application simplicity through automated dispensing systems.
3Stability of the object's composition
If fastening parts and cooling equipment are added to battery modules, then the structural integrity is improved, but the manufacturing cost and volume increase
Solution Approach 1:
The patent merges the functions of adhesion and structural support into a single adhesive resin composition system. The cured resin not only bonds battery cells together but also provides structural stability and thermal management interface, eliminating the need for separate fastening parts and reducing overall device complexity.
Data Source
AI summary
A method for manufacturing a battery cell stack according to exemplary embodiments of the present invention includes an application step of spraying an adhesive resin composition on one surface of a battery cell in one direction by a plurality of nozzles, wherein the nozzles are disposed in a direction different from the one direction, and at least two nozzles of the plurality of nozzles apply the adhesive resin composition in amounts different from each other. Thereby, the adhesive resin composition is applied to one surface of a non-flat battery cell, and the application amount is controlled according to portions to be applied, so that the one surface may bring into contact with another surface of another battery cell adhered thereon over an entire area in which the adhesive resin composition is applied.