Fastener-free Battery Modules Using Adhesive Bonding
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Solution Overview
Problem
Battery electric vehicles face long charge times due to low energy density in battery packs, which can be attributed to the use of fasteners that occupy valuable packaging space, necessitating a solution that eliminates or reduces the need for fasteners in battery module assembly.
Innovation Solution
The use of adhesives for structural support and assembly of battery modules, including multiple types of adhesives for bonding battery cells to a carrier, side wall, current collector, and cooling plate, allowing for efficient transfer of mechanical, thermal, and electrical loads without the need for fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fasteners are used to assemble battery modules, then structural support and mechanical strength are achieved, but packaging space is reduced and energy density decreases
Solution Approach 1:
The patent replaces the mechanical fastening system (screws, clips, or other mechanical fasteners) with an adhesive bonding system. The adhesive bonds the battery cells to the module housing and internal components, providing structural support without requiring the physical space needed for mechanical fasteners. This substitution eliminates the need for fastener holes, mounting features, and the fasteners themselves, thereby maximizing packaging space for battery cells.
Solution Approach 2:
The patent changes the bonding mechanism from mechanical (fasteners) to chemical (adhesive bonding). This parameter change in the assembly method allows for continuous bonding surfaces rather than discrete fastener points, enabling more efficient use of space and improving energy density while maintaining structural integrity through the adhesive's bonding strength.
2Strength
If fasteners are used for battery module assembly, then mechanical connection is achieved, but energy density and vehicle range are reduced
Solution Approach 1:
The patent substitutes mechanical fastening with adhesive bonding, eliminating the volume occupied by fasteners and their mounting features. This increases the proportion of the module volume that can be dedicated to battery cells, directly improving energy density and extending vehicle range while maintaining adequate mechanical connection through the adhesive's bonding properties.
Solution Approach 2:
The adhesive used in the patent serves multiple functions simultaneously: it provides structural bonding to replace mechanical fasteners, fills gaps between components, provides thermal management pathways, and ensures electrical isolation where needed. This multi-functionality consolidates what would otherwise require multiple separate components, maximizing space for energy-storing battery cells.
3Adaptability or versatility
If multiple types of adhesives are used for bonding different components, then multiple functional requirements are met, but assembly complexity increases
Solution Approach 1:
The patent applies different adhesive formulations to different locations and bonding requirements within the module. For example, high-strength structural adhesives are used for critical load-bearing bonds, while thermally conductive adhesives are used for heat dissipation pathways, and electrically insulating adhesives are used where electrical isolation is needed. This localized optimization of adhesive properties ensures each bonding location receives the appropriate functionality without requiring a completely different adhesive system throughout.
Solution Approach 2:
The patent segments the adhesive bonding process into distinct stages or zones, allowing different adhesive types to be applied systematically to different components or bonding surfaces. This segmentation enables specialized adhesive selection for each bonding interface while maintaining an organized, manageable assembly process rather than requiring a single complex adhesive to perform all functions simultaneously.
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 increases energy density by eliminating the space required for fasteners, enabling longer vehicle ranges and improved packaging efficiency while ensuring reliable structural, thermal, and electrical performance through the use of specialized adhesives that meet multiple functional requirements.
Implementation Method 1
A first type of adhesive bonds a first side of the carrier to the plurality of battery cells
Implementation Method 2
a second type of adhesive bonds the side wall to the plurality of battery cells
Implementation Method 3
a third type of adhesive bonds the current collector to a second side of the carrier
Implementation Method 4
a fourth type of adhesive bonds the plurality of battery cells to the cooling plate. The cooling plate is configured to transfer heat from the plurality of battery cells
Data Source
AI summary
A battery system includes battery cells arranged and adhered to a carrier. One or more side walls are bonded with adhesive to the battery cells to provide support, and a current collector assembly is also adhered on one axial side of the battery cells. One or more dividers may be included to maintain electrically isolation between the parallel connected battery cell groups. The other axial side of the battery cells is adhered to a cooling plate. A similar structure is bonded with adhesive to the other side of the cooling plate to form a compact battery system. Shear walls, busbars, terminal busbars, and an isolation bracket with a mounted Electronic Control Unit are bonded with adhesive to the assembly to form the battery system. Each adhesive, or type of adhesive, may exhibit specified criteria and requirements such as strength, thermal conductivity, electronic conductivity, curing requirements, or a combination thereof.