Battery Cell Thermal Bonding With Graded Adhesive Properties
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Solution Overview
Problem
Existing methods for forming thermally conductive connections between battery cells and temperature-regulating bodies in battery modules lack the ability to adapt robustness, flexibility, and thermal conductivity to specific thermal behaviors, often resulting in inefficient heat management and potential stress due to mismatched coefficients of thermal expansion.
Innovation Solution
A method involving an adhesive with multiple components, where the proportion of these components is varied to create an inhomogeneous material bond, allowing for gradients in thermal conductivity, hardness, elasticity, and chemical resistance, and applied in a manner that forms inhomogeneities in both the connecting plane and height direction, reducing stress and optimizing thermal performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a uniform material bond is formed between battery cells and temperature-regulating body, then the manufacturing process is simple, but the thermal conductivity and mechanical properties cannot be adapted to specific thermal requirements
Solution Approach 1:
The patent applies adhesive components with different proportions in different regions of the battery module. Specifically, a first proportion of adhesive components is applied in a first region, while a second proportion (different from the first) is applied in a second region. This creates spatially varying material properties that adapt to local thermal requirements, resolving the contradiction between uniform manufacturing simplicity and localized thermal adaptation.
Solution Approach 2:
The patent changes the compositional parameters of the adhesive by varying the proportions of adhesive components across different regions. By adjusting the ratio and amount of adhesive substances in different areas, the thermal conductivity and mechanical properties are tuned to match specific thermal behaviors required in different parts of the battery module, enabling adaptability without requiring entirely different adhesive formulations.
2Reliability
If adhesive components are applied in different proportions to different regions, then thermal performance is optimized, but the manufacturing process becomes more complex
Solution Approach 1:
The patent segments the adhesive application process into distinct regions (first region and second region) with different adhesive component proportions. This segmentation allows for optimized thermal performance in each region while maintaining a systematic manufacturing approach. The segmented application can be implemented through controlled dispensing techniques that, while requiring additional process steps, follow a repeatable pattern that balances manufacturing complexity with thermal management effectiveness.
3Adaptability or versatility
If a material bond with inhomogeneous adhesive distribution is formed, then robustness and flexibility are adapted to thermal behavior, but the adhesive force distribution becomes inhomogeneous
Solution Approach 1:
The patent deliberately creates local quality variations in the adhesive bond by applying different proportions of adhesive components in different regions. This inhomogeneous adhesive distribution is not a manufacturing defect but a designed feature that adapts the material bond's robustness and flexibility to local thermal behaviors. The controlled inhomogeneity resolves the contradiction by making adhesive force variation the mechanism for achieving adaptability.
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 method enables the formation of a robust, flexible, and thermally conductive bond that adapts to specific thermal requirements, reducing stress and enhancing heat management in battery modules, suitable for series production and optimizing thermal performance.
Implementation Method 1
The at least one first component of the adhesive and the at least one second component of the adhesive are expediently mixed with one another before the application.
Implementation Method 2
a material bond can be formed between the temperature-regulating body and the plurality of battery cells... the plurality of battery cells is connected, in particular thermally conductively connected, to the temperature-regulating body
Data Source
AI summary
A method for forming a thermally conductive connection between a plurality of battery cells (2) and a temperature-regulating body (1) of a battery module (100), wherein, in a first method step, an adhesive (3) comprising at least one first component (31) and at least one second component (32) is applied to the temperature-regulating body (1) or to the plurality of battery cells (2), wherein a first proportion (41) of the at least one first component (31) and/or a second proportion (42) of the at least one second component (32) is changed during the application of the adhesive (3) over the temperature-regulating body (1) or the plurality of battery cells (2), wherein, in a second method step, the plurality of battery cells (2) is connected to the temperature-regulating body (1) in such a way that an inhomogeneous material bond is formed between the plurality of battery cells (2) and the temperature-regulating body (1).