Pouch Cell Adhesive Activation for Lighter Battery Module Assembly
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Solution Overview
Problem
The production of lithium secondary battery modules for vehicles is hindered by the need for costly fastening components and cooling equipment, which increase volume, weight, and reduce power efficiency.
Innovation Solution
A method of manufacturing battery modules where inactive adhesive layers on pouch cells are activated by energy to form adhesive layers between cells, eliminating the need for liquid adhesives and reducing material disposal costs, and allowing for simpler stacking processes without additional adhesive application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fastening components and cooling equipment are used to assemble battery modules, then the structural integrity and cooling function are improved, but the volume, weight, and production cost increase
Solution Approach 1:
The pouch case integrates both structural containment and cooling functions by incorporating cooling channels directly into the case structure, eliminating the need for separate cooling equipment and fastening components while maintaining structural integrity and thermal management
Solution Approach 2:
The pouch case serves multiple functions simultaneously: it provides structural support, thermal management through integrated cooling channels, and electrical insulation, replacing multiple separate components with a single multi-functional element
2Reliability
If fastening components and cooling equipment are used to assemble battery modules, then the structural integrity and cooling function are improved, but the production cost increases
Solution Approach 1:
The pouch case integrates both structural containment and cooling functions by incorporating cooling channels directly into the case structure, eliminating the need for separate cooling equipment and fastening components while maintaining structural integrity and thermal management
Solution Approach 2:
The invention extracts and eliminates unnecessary fastening components and separate cooling equipment from the battery module assembly, retaining only the essential pouch case structure that performs both structural and thermal management functions
3Strength
If liquid adhesive is used to bond battery cells, then the bonding strength is improved, but the material disposal cost and process complexity increase
Solution Approach 1:
The invention replaces the chemical adhesive bonding system with a mechanical interlocking system where the pouch case structure itself provides the bonding mechanism through integrated cooling channels that physically interlock with adjacent cells, eliminating liquid adhesive and its associated disposal costs
Solution Approach 2:
The pouch case is designed as a disposable structural component that provides both containment and bonding functions, eliminating the need for separate adhesive materials that require disposal and management
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 method enhances productivity by reducing material and process line management costs, improving operational efficiency, and maintaining power efficiency while minimizing the need for additional fastening components.
Implementation Method 1
an energy is applied to the inactive adhesive layer of each of the battery cells to form an adhesive layer having an increased adhesion
Implementation Method 2
a hot-melt adhesive may be coated entirely on an outer surface of the pouch sheet
Data Source
AI summary
In a method of manufacturing a battery module, a plurality of battery cells each of which includes a pouch case including an inactive adhesive layer formed on an outer surface thereof and an electrode assembly accommodated in the pouch case are prepared. An energy is applied to the inactive adhesive layer of each of the battery cells to form an adhesive layer having an increased adhesion. The battery cells including the adhesive layer are stacked so that the adhesive layer is interposed between neighboring battery cells.