Utilizing vacuum to pre-compress foam to enable cell insertion during HV battery module assembly
View Patent ↗A method of assembling a battery module assembly includes a step of preparing a plurality of battery cell stacks. Each battery cell stack is constructed by positioning a pre-compressed foam unit interposed between a first battery cell and a second battery cell. Each battery cell stack is positioned in a receiving frame. After such positioning, the pre-compressed foam unit of each battery cell stack is expanded.
1. A method of assembling a battery module assembly, the battery module assembly including a plurality of battery cell elements, the method comprising:
preparing a plurality of battery cell stacks, each battery cell stack constructed by positioning a pre-compressed foam unit interposed between a first battery cell and a second battery cell, each pre-compressed foam unit including a vacuum sealed package having a spout and a foam pad positioned within the vacuum sealed package;
positioning each battery cell stack in a receiving frame; and
expanding the pre-compressed foam unit of each battery cell stack.
2. The method of claim 1 wherein the vacuum sealed package comprises a polyester.
3. The method of claim 1 wherein the foam pad is expanded by severing the spout.
4. The method of claim 1 wherein the foam pad comprises a component selected from the group consisting of polyurethane, polyester, polyether, and combinations thereof.
5. The method of claim 1 wherein the receiving frame includes a plurality of cooling fins.
6. The method of claim 5 wherein the receiving frame further includes a heat sink contacting the cooling fins.
7. The method of claim 6 wherein the cooling fins are interposed between battery cell stacks.
8. The method of claim 6 wherein the cooling fins are fusion bonded to the heat sink.
9. The method of claim 5 comprising split-fin cooling systems that include the cooling fins.
10. The method of claim 1 wherein the receiving frame receives the plurality of battery cell stacks.