UV-Responsive Adhesive for Battery Pack Assembly
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Solution Overview
Problem
The insertion and removal of multi-cell battery packs into battery-powered devices are complicated by irregular bay placements and cell dimensions, leading to difficulties in achieving a tight fit and facilitating re-insertion or removal of cells due to adhesive bonding during assembly.
Innovation Solution
The use of a two-liner configuration with a UV-responsive adhesive, where battery cells are bonded to a first liner with a strong adhesive force that weakens upon UV exposure, allowing for easy removal, and pads bonded to a second liner with a weaker adhesive force for convenient handling and placement within the device chassis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive bonding is used to secure battery cells to the liner during assembly, then secure bonding is achieved, but removal and re-insertion of cells becomes difficult
Solution Approach 1:
The adhesive's bonding strength is made dynamic through UV light exposure. Before UV exposure, the adhesive provides strong bonding to secure cells during assembly and transport. After UV exposure, the adhesive's bonding strength decreases, enabling easy removal and re-insertion of cells. This dynamic property allows the same adhesive to serve different functions at different stages of the product lifecycle.
Solution Approach 2:
The adhesive's key parameter (bonding strength) is changed by applying UV light. The adhesive is designed to undergo a chemical or physical transformation when exposed to UV radiation, resulting in a reduction of its adhesive properties. This parameter change enables the transition from a strong-bonding state during assembly to a weak-bonding state during service and disposal.
2Strength
If strong adhesive force is used to bond battery cells to the liner, then secure bonding is achieved, but transportation and handling become complicated
Solution Approach 1:
The adhesive provides strong bonding during manufacturing and assembly operations, then becomes easy to manipulate after UV exposure. This dynamic behavior simplifies transportation and handling at different stages: strong bonding during assembly, then controlled release during final installation or disposal.
Solution Approach 2:
The adhesive is applied in advance during assembly with strong bonding properties, then the UV exposure is performed as a preliminary action before final installation. This preliminary UV treatment prepares the adhesive for its second function (easy removal) before the battery pack is deployed, simplifying subsequent handling and installation operations.
3Stability of the object's composition
If battery cells are permanently bonded to the liner, then secure assembly is achieved, but insertion into irregular bays and re-positioning becomes difficult
Solution Approach 1:
The adhesive's bonding characteristics are made dynamic to match different operational requirements. During assembly, the adhesive provides stable bonding to ensure proper cell positioning. After UV exposure, the bonding becomes flexible and reversible, allowing for easy adjustment, re-positioning, and removal of cells from irregular battery bays.
Solution Approach 2:
The adhesive's bonding strength parameter is changed through UV exposure to enable adaptability. The same adhesive material exhibits different bonding characteristics before and after UV treatment, allowing the assembly to transition from a stable, fixed state during manufacturing to a flexible, adjustable state during installation and service.
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
Facilitates the transportation and proper insertion of battery packs into devices by allowing for controlled adhesive weakening with UV light exposure, simplifying the insertion and removal processes while maintaining secure bonding during operation.
Implementation Method 1
a first adhesive configured to provide a first adhesive force between each of the battery cells and the first surface before exposure to ultraviolet (UV) light, and a second adhesive force after exposure to UV light
Data Source
AI summary
The disclosed technology relates to a battery pack assembly that includes multiple battery cells. In some aspects, each cell is bonded to a first surface of a first liner (e.g., a cosmetic liner) via a first adhesive. The first adhesive is configured to provide a first adhesive force between each of the battery cells and the first surface before exposure to ultraviolet (UV) light and a second adhesive force after exposure to UV light, and wherein the second adhesive force is less than the first adhesive force. A battery pallet and method of manufacturing are also provided.