Battery Cell Tab Thermal Barrier Insertion for Fast Gap Filling
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Solution Overview
Problem
Existing methods for providing thermal barriers between battery cell tabs in traction battery packs are inefficient and often require additional time for curing or expansion, and may not effectively fill gaps between tabs.
Innovation Solution
A method and apparatus using a preformed thermal barrier material, such as compressible foam, inserted through a loader or compression tube, which is compressed to fit between adjacent battery cell tabs and expands to fill the gap, utilizing a non-conductive insertion structure and automated plungers to facilitate simultaneous installation across multiple tabs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional thermal barrier installation methods are used, then thermal protection is provided, but installation efficiency is low and requires additional curing time
Solution Approach 1:
The thermal barrier member is preformed with an expandable structure before insertion. The compression tube is pre-positioned in the gap between tabs, and the thermal barrier is pre-loaded into the tube. This preliminary preparation enables rapid deployment without on-site curing time, as the expansion action itself activates the thermal barrier functionality immediately upon insertion.
Solution Approach 2:
The thermal barrier member utilizes a phase transition mechanism from compressed state to expanded state. The expandable structure transitions from a compacted configuration during insertion to an expanded configuration that fills the gap between tabs. This phase transition provides immediate thermal protection without requiring chemical curing time, resolving the time loss issue while maintaining productivity gains.
2Productivity
If preformed thermal barrier material is compressed for insertion, then installation speed increases, but complete gap filling may be compromised
Solution Approach 1:
The thermal barrier member is nested within the compression tube during insertion. The compression tube acts as a delivery mechanism that protects the preformed thermal barrier during transport and positioning. Upon deployment, the thermal barrier expands from its nested state to fully fill the gap, ensuring complete coverage while maintaining fast installation speed through the pre-compressed configuration.
Solution Approach 2:
The system transitions from a static compressed state during insertion to a dynamic expanded state after placement. The expandable structure is designed to dynamically adjust from a compacted form that fits through the compression tube to an expanded form that completely fills the gap between tabs. This dynamic transformation ensures both installation speed and gap filling completeness are achieved.
3Manufacturing precision
If multiple tabs are installed sequentially, then installation precision is maintained, but overall installation time increases
Solution Approach 1:
Multiple compression tubes with preformed thermal barrier members are merged into a single automated installation system. The system simultaneously deploys multiple thermal barriers across multiple tab gaps in one coordinated action. This merging of multiple installation operations into a single simultaneous process maintains precision through automated positioning while dramatically reducing overall installation time by eliminating sequential operations.
Solution Approach 2:
The automated installation system maintains continuous useful action by simultaneously installing thermal barriers across multiple tabs in one coordinated motion. Rather than pausing between individual tab installations, the system performs continuous simultaneous installation across all tabs, eliminating idle time between operations while maintaining precision through synchronized automated control of all compression tubes.
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
This solution provides efficient and automated installation of thermal barriers, ensuring complete gap filling and improved thermal protection without the need for curing time, enhancing the assembly process and thermal performance of traction battery packs.
Implementation Method 1
pushing the preformed member through the at least one loader and into an open area between adjacent battery cell tabs such that the preformed member expands to fill the open area
Implementation Method 2
the thermal barrier material comprises a compressible foam material, and including compressing the preformed member during insertion through the at least one loader
Data Source
AI summary
A method and apparatus comprise an insertion apparatus that has at least one loader. A preformed member comprised of a thermal barrier material is inserted into the at least one loader. The preformed member is pushed through the at least one loader and into an open area between adjacent battery cell tabs such that the preformed member expands to fill the open area.