Cooling Element Cell Bonding for Precise Battery Pack Assembly
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Solution Overview
Problem
The production of electrical accumulators for partially or fully electrically operated motor vehicles is complex due to the large number of accumulator cells, electrical contacting, and cooling requirements, making rapid and reliable manufacturing challenging.
Innovation Solution
A method involving a cooling element with a longitudinal axis, adhesive application, and a counterholder to support and align accumulator cells, forming a crescent-shaped adhesive gap for uniform distribution, allowing precise assembly and reduced installation space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large number of accumulator cells are assembled with cooling elements and electrical contacting, then the electrical accumulator meets functional requirements, but the production process becomes complex and time-consuming
Solution Approach 1:
The cooling element is divided into modular sections with standardized interfaces, allowing the accumulator to be assembled from repeating units. Each module contains a defined number of accumulator cells arranged around a cooling element segment, simplifying the overall assembly process while maintaining full functionality.
Solution Approach 2:
The cooling element serves multiple functions simultaneously: it provides thermal management through fluid channels, acts as a structural support for mounting accumulator cells, and facilitates electrical connections through integrated contact points. This multi-functionality reduces the number of separate components needed.
2Manufacturing precision
If accumulator cells are precisely aligned on the cooling element, then manufacturing precision is improved, but the assembly process becomes more complex
Solution Approach 1:
Alignment features such as positioning protrusions and recesses are pre-formed on the cooling element and accumulator cells during manufacturing. These features automatically guide correct alignment when components are assembled, eliminating the need for complex alignment procedures during assembly while ensuring high precision.
Solution Approach 2:
A standardized interface element is introduced between the cooling element and accumulator cells that provides precise geometric reference surfaces. This intermediary component acts as a mediator that ensures accurate positioning without requiring complex direct alignment between the main components.
3Strength
If adhesive is applied to the entire lateral face, then bonding strength is maximized, but adhesive usage and installation space increase
Solution Approach 1:
Adhesive application is concentrated at specific high-stress contact zones rather than being distributed uniformly across the entire lateral face. Positioning features create localized bonding areas where adhesive is most needed for structural integrity, reducing overall adhesive consumption while maintaining sufficient bonding strength.
Solution Approach 2:
Instead of applying adhesive to the entire surface area, the solution uses partial action by targeting only the critical bonding regions. The adhesive is applied in controlled amounts at specific locations where it provides maximum bonding effectiveness, avoiding waste in areas where bonding is not required.
4Manufacturing precision
If the cooling element is supported in a form-fitting manner, then alignment precision is improved, but the support structure becomes more complex
Solution Approach 1:
The support structure uses nested positioning features where smaller geometric elements are integrated into larger components. For example, positioning protrusions on the cooling element fit into corresponding recesses on the support structure, creating a hierarchical nesting arrangement that provides precise form-fitting support without requiring a complex separate support system.
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
Enables rapid, reliable, and uniform manufacturing of electrical accumulators with consistent quality, reducing adhesive usage and installation space while ensuring precise alignment and efficient cooling.
Implementation Method 1
applying adhesive to the first lateral face
Implementation Method 2
heat from the storage elements is able to be transmitted to the fluid
Data Source
AI summary
A method for producing an electrical accumulator includes the steps of: providing a cooling element which extends along a longitudinal axis and has a first side face and a second side face; applying adhesive onto the first side face; arranging at least one energy-storage cell on the first side face while, particularly interlockingly, supporting the cooling element from the second side face.