Dual Adhesive Bonding for Battery Assembly Handling
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Solution Overview
Problem
Existing battery system manufacturing processes face challenges in handling components due to the curing requirements of adhesives, as high-strength adhesives often require long curing times, while fast-curing adhesives lack sufficient strength and are brittle, making it difficult to balance quick handling with strong bonding.
Innovation Solution
The method involves applying a slow-curing adhesive and a fast-curing adhesive in non-overlapping areas, where the fast-curing adhesive provides initial structural support during assembly, and the slow-curing adhesive achieves high-strength bonding over a longer period, allowing for efficient manufacturing processes without the need for buffering zones or complex tooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a slow-curing high-strength adhesive is used, then bonding strength is improved, but handling time and manufacturing efficiency deteriorate due to long curing time
Solution Approach 1:
The bonding interface is segmented into two distinct zones: a first area receiving slow-curing high-strength adhesive for ultimate bond strength, and a second area receiving fast-curing adhesive for rapid initial bonding and handling. This spatial segmentation allows each adhesive type to perform its specialized function without compromising the other.
Solution Approach 2:
Different adhesive properties are applied to different local areas of the bonding interface. The first area uses slow-curing adhesive optimized for strength, while the second area uses fast-curing adhesive optimized for quick handling. Each local region has tailored adhesive characteristics matching its specific functional requirements.
2Loss of time
If a fast-curing adhesive is used, then handling time is reduced, but bonding strength deteriorates due to brittleness and insufficient strength
Solution Approach 1:
The bonding interface is divided into two functional zones: a first area for slow-curing high-strength adhesive providing ultimate bond strength, and a second area for fast-curing adhesive providing rapid initial bonding. This segmentation allows fast-curing adhesive to fulfill its time-efficient purpose without being required to provide full structural strength.
Solution Approach 2:
Fast-curing adhesive is applied locally to the second area where quick handling is needed, while slow-curing high-strength adhesive is applied to the first area where ultimate bond strength is critical. Each adhesive's local application optimizes its inherent properties for the specific functional requirement of that region.
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 approach enables quick handling and manipulation of battery system components during manufacturing while ensuring strong, durable bonds, reducing manufacturing time and eliminating the need for complex tooling, thus optimizing the assembly process.
Implementation Method 1
The first adhesive is a one-part or two-part slow-curing adhesive having a first curing time
Implementation Method 2
The second adhesive is a UV-cure adhesive, and the sidewall includes a transmittance sufficient to allow UV light to pass through to UV-cure the second adhesive during the curing schedule
Data Source
AI summary
A method for making a battery system includes applying fast-cure and slow-cure adhesives to interfaces between components. The fast-cure adhesive allows manipulation of the assembly during manufacturing while the slow-cure adhesive cures. The slow-cure adhesive provides desired strength and toughness as needed during use of the final assembly. The fast-cure adhesive and slow-cure adhesive have respective curing schedules. The fast-cure adhesive includes a moisture-curing adhesive or any other suitable adhesive curing on the order of seconds such as UV-activated or cyanoacrylate adhesives. The slow cure adhesive includes any suitable structural adhesive such as a two-part mix-cure epoxy or acrylic. The components adhered using the fast-cure adhesive and slow-cure adhesive include side wall sections, battery cells, mounting bracket, bus bars, or any other suitable components. The fast-cure and slow-cure adhesives are applied in any suitable pattern such as, for example, beads, dots, paths, non-intersecting paths, or any other suitable application shape.