Lithium-Ion Cell Module Assembly Using Adhesive Collector Plates
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Solution Overview
Problem
Existing battery pack designs face challenges in efficiently packaging and connecting lithium-ion battery cells, particularly in providing a robust and flexible solution for various applications, including outdoor power equipment and vehicles.
Innovation Solution
The design of a cell module assembly (CMA) that includes a top frame, a bottom frame, multiple lithium-ion battery cells, top and bottom collector plates, and curable adhesive, which allows for secure adhesion and electrical connection of the battery cells in parallel, eliminating the need for fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional fasteners are used to connect battery cells, then mechanical strength is improved, but device complexity and assembly time increase
Solution Approach 1:
The patent replaces the mechanical fastening system (screws, clips, or other mechanical connectors) with a chemical bonding system using curable adhesive. The adhesive is applied to the collector plates and bonds to the battery cell terminals, creating a secure mechanical connection through chemical adhesion rather than mechanical interlocking. This substitution eliminates the need for fasteners while maintaining connection strength and simplifying the overall assembly.
2Reliability
If multiple fasteners are used to secure battery cells, then reliability is improved, but manufacturing time and productivity are reduced
Solution Approach 1:
The mechanical fastening system is replaced with a curable adhesive system that can be applied continuously to bond collector plates to battery cell terminals. The adhesive application process can be automated and performed in a single step, eliminating the multiple fastener installation steps required in traditional systems. This substitution maintains reliable electrical and mechanical connections while significantly reducing assembly time and increasing manufacturing productivity.
3Stability of the object's composition
If a rigid frame structure is used to hold battery cells, then structural stability is improved, but adaptability to different applications is reduced
Solution Approach 1:
The patent employs a flexible adhesive bonding system rather than a rigid mechanical fastening system. The curable adhesive provides structural stability while allowing the battery module design to be adapted to different configurations and applications. The adhesive can accommodate variations in cell dimensions, spacing, and arrangement, enabling the same basic module design to serve multiple applications without requiring rigid, application-specific fastener designs.
4Reliability
If complex fastening mechanisms are used to connect collector plates, then electrical connection reliability is improved, but ease of manufacture is reduced
Solution Approach 1:
Complex mechanical fastening mechanisms are replaced with a simple curable adhesive application process. The adhesive is applied to the collector plate surfaces and bonds to the battery cell terminals, creating reliable electrical connections through direct chemical adhesion. This substitution eliminates complex fastening mechanisms with multiple moving parts or assembly steps, making the manufacturing process simpler, faster, and easier to automate while maintaining electrical connection reliability.
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 CMA provides a compact, efficient, and flexible solution for battery packs, enabling secure adhesion and electrical connection of battery cells, which enhances the reliability and performance of battery packs for various applications.
Implementation Method 1
The multiple lithium-ion battery cells are each adhesively coupled to the bottom frame and the top frame
Implementation Method 2
The curable adhesive is received within each window in the first multiple pockets. The curable adhesive contacts the top frame and each of the multiple lithium-ion battery cells in at least two separate locations to adhesively couple each lithium-ion battery cell to the top frame
Data Source
AI summary
A cell module assembly includes a first frame having a first plurality of pockets, a second frame spaced apart from the first frame and having a second plurality of pockets, a plurality of lithium-ion battery cells coupled to and extending between the second frame and the first frame, a first collector plate electrically connected to the plurality of lithium-ion battery cells and coupled to the first frame by a first curable adhesive, and a second collector plate electrically connected to the plurality of lithium-ion battery cells and coupled to the second frame by a second curable adhesive. Each one of the plurality of lithium-ion battery cells is received within a respective one of the first plurality of pockets and a respective one of the second plurality of pockets.