Thermally Detachable EV Battery Pack Adhesive for Clean Separation
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Solution Overview
Problem
Existing methods for detaching EV battery packs from thermoset adhesive layers are inefficient, often causing damage and requiring hazardous chemicals, especially in high surface area attachments.
Innovation Solution
A thermally detachable multilayer adhesive composition comprising thermoplastic primer layers with transition temperatures between 60°C to 120°C and thermoset adhesive layers, which can be heated to soften or melt the primer layers for easy detachment without damaging the battery pack.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If physical removal methods (prying, cutting, or laser ablation) are used to detach EV battery bonded to thermoset adhesive, then detachment can be achieved, but damage to adhered components occurs and the process is complex
Solution Approach 1:
The patent changes the physical-chemical state of the adhesive system by introducing a thermoplastic primer layer with a specific transition temperature (60-120°C). This primer layer transitions from a bonded state at operating temperatures to a detached state when heated above its transition temperature, enabling clean separation without mechanical damage. The bonding strength parameter is dynamically adjusted through temperature control.
Solution Approach 2:
The thermoplastic primer layer undergoes a phase transition at its transition temperature (60-120°C). Below this temperature, the primer maintains strong adhesion; above this temperature, the primer softens or melts, causing loss of bonding strength and enabling detachment. This phase transition provides a controlled, non-destructive detachment mechanism.
2Ease of operation
If solvents or acids are used to remove thermoset adhesive, then chemical bonding can be broken, but chemical hazards are generated and penetration into adhesive layer is limited
Solution Approach 1:
The patent converts the typically harmful effect of heat (which could damage battery components) into a beneficial detachment mechanism. By carefully selecting a thermoplastic primer with a transition temperature below the thermal sensitivity threshold of battery components (60-120°C), heat becomes a controlled, non-hazardous detachment agent that avoids the chemical hazards of solvents and acids.
Solution Approach 2:
The thermoplastic primer layer serves as an intermediary between the thermoset adhesive and the battery components. This primer layer is designed to be thermally responsive, acting as a mediator that can be selectively deactivated through heating to enable detachment, while the thermoset adhesive maintains its strong bonding properties throughout the process.
3Area of stationary object
If common detachment methods are used on high surface area attachments, then detachment can be attempted, but effectiveness is reduced and component damage increases
Solution Approach 1:
The patent segments the adhesive system into distinct functional layers: a thermoset adhesive layer providing strong bonding and a thermoplastic primer layer providing controlled detachment capability. This segmentation allows the large surface area attachment to maintain strong bonding during operation while enabling uniform, controlled detachment across the entire surface when heated, improving effectiveness without increasing component damage risk.
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 allows for efficient and minimally damaging detachment of EV battery packs by heating the multilayer composition, reducing the bonding strength and enabling mechanical separation without exposing the system to hazardous chemicals.
Implementation Method 1
heating the multilayer composition to a detachment temperature above 60° C., the multilayer composition comprising one or more thermoplastic primer layers having a transition temperature in the range of 60° C. to 120° C.
Implementation Method 2
heating the multilayer composition to a detachment temperature above 60° C.... soften or melt the primer layers for easy detachment
Data Source
AI summary
Methods may include detaching a battery pack adhered to a substrate by a multilayer composition, including: heating the multilayer composition to a detachment temperature above 60° C. the multilayer composition comprising one or more thermoplastic primer layers having a transition temperature in the range of 60° C. to 120° C., and one or more thermoset adhesive layers; and separating one or more layers of the multilayer composition to detach the battery pack from the substrate, wherein the substrate has a surface energy of 35 dynes/cm or greater.