Laser Bonding Thermoplastic Battery Modules Energy Absorbing Insert
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Solution Overview
Problem
Existing methods for bonding thermoplastic components in lithium ion battery modules are inefficient, as they require solvents, adhesives, or high-power ultrasonic energy, and lack precision, making them unsuitable for high-performance battery systems.
Innovation Solution
A method involving an energy absorbing insert positioned between thermoplastic layers, where laser energy is applied to melt and fuse the layers, creating a precise weld joint, utilizing thermoplastic components that are transparent or semi-transparent to allow energy absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If solvents or adhesives are used for bonding thermoplastic components, then the bonding process is simple to implement, but the bonding precision and structural integrity are insufficient
Solution Approach 1:
The patent replaces mechanical bonding methods (solvents, adhesives) with laser-based energy absorption and melting. The laser energy is absorbed by the thermoplastic material to melt and fuse components together, achieving precise bonding without chemical agents. This substitution of mechanical/chemical systems with optical/thermal systems resolves the contradiction by providing both precision and process simplicity.
Solution Approach 2:
The patent utilizes phase transition of thermoplastic materials from solid to molten state through laser heating, then back to solid upon cooling to create strong bonds. This controlled phase transition enables precise bonding by melting the thermoplastic at the bonding interface and allowing it to fuse with adjacent components, achieving high bonding precision without complex adhesive application processes.
2Manufacturing precision
If high-power ultrasonic energy is used for bonding, then bonding strength can be achieved, but the process lacks precision and causes excessive energy consumption
Solution Approach 1:
The patent applies laser energy locally to specific bonding locations on thermoplastic components. The laser can be focused on precise areas requiring bonding, heating only the necessary regions rather than applying ultrasonic energy across entire component surfaces. This localized energy application achieves both bonding precision and reduced overall energy consumption.
Solution Approach 2:
The patent replaces ultrasonic vibration-based bonding with laser-based thermal bonding. Instead of using high-power ultrasonic waves that require significant energy input, the system uses concentrated laser energy to melt and fuse thermoplastic materials at precise locations, reducing total energy consumption while maintaining bonding strength and improving precision.
3Reliability
If traditional bonding methods are used, then the process can handle various materials, but the sealing and structural integrity of battery systems are insufficient
Solution Approach 1:
The patent uses laser-induced phase transition of thermoplastic materials to create seamless bonds. By melting the thermoplastic at bonding interfaces and allowing controlled solidification, the process creates continuous, gap-free joints that provide superior sealing integrity compared to adhesive-based methods. This phase transition approach maintains manufacturing simplicity while dramatically improving reliability.
Solution Approach 2:
The patent replaces chemical bonding systems (adhesives, solvents) with laser-based thermal fusion. This substitution creates direct material-to-material bonds without intermediate chemical layers, resulting in stronger, more reliable joints with better sealing properties. The process remains easy to manufacture with automated laser systems, resolving the contradiction between reliability and manufacturing ease.
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 provides a precise and efficient method for bonding thermoplastic components in lithium ion battery modules, enhancing the sealing and structural integrity of battery systems for electric vehicles and other high-voltage applications.
Implementation Method 1
Energy is applied to the energy absorbing insert to melt the energy absorbing insert and thereby fuse the first thermoplastic layer to the second thermoplastic layer
Implementation Method 2
Energy is applied to the energy absorbing insert to melt the energy absorbing insert
Implementation Method 3
The first thermoplastic layer is a transmissive or semi-transmissive layer configured to allow the energy the pass through the first thermoplastic layer for absorption by the energy absorbing insert
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
A method for bonding components of a lithium ion battery module includes positioning an energy absorbing insert adjacent to a first thermoplastic layer of the lithium ion battery module and to a second thermoplastic layer of the lithium ion battery module. Energy is applied to the energy absorbing insert to melt the energy absorbing insert and thereby fuse the first thermoplastic layer to the second thermoplastic layer. The first thermoplastic layer is a transmissive or semi- transmissive layer configured to allow the energy the pass through the first thermoplastic layer for absorption by the energy absorbing insert.