Embedded optics in modular assemblies

Patent metadata

Field	Value
Publication number	US-2016336565-A1
Application number	US-201615224074-A
Country	US
Kind code	A1
Filing date	Jul 29, 2016
Priority date	Apr 12, 2012
Publication date	Nov 17, 2016
Grant date	—

Abstract

An enhanced multi object potting fixture for exposure to a curing modality that sets an adhesive includes a fixture housing supporting a plurality of objects, the fixture housing having a wall defining a plurality of bonding wells with each the bonding well receiving a first portion of one of the objects, each the bonding well including an aperture in the wall proximate the first portion wherein each bonding well includes a target zone for selective cure of the adhesive to inhibit the adhesive from exiting the aperture; and a fixture enhancement structure integrated into the wall concentrating the curing modality in each the target zone.

First claim

What is claimed is:

1 . An enhanced bonding method, the method comprising the steps of:
(a) dispensing a high-wettability adhesive into a module fixture populated with a plurality of battery cells wherein the module fixture provides a plurality of bonding wells with each bonding well accepting a first portion of one or more of the plurality of battery cells with the module fixture including one or more apertures communicated with one or more of the plurality of bonding wells, the high-wettability adhesive being selectively curable upon application of an ultraviolet (UV) radiation field; (b) applying the UV radiation field generally uniformly to the module fixture; and (c) concentrating the generally uniformly applied curing modality into a plurality of target zones corresponding to the plurality of bonding wells using a fixture enhancement structure integrated into the module fixture that optically concentrates the UV radiation field towards the plurality of target zones.

2 . The enhanced bonding method of claim 1 , further comprising the fixture enhancement structure reflecting the UV radiation field towards each target zone and away from portions of the one or more bonding wells not in the target zone.

3 . The enhanced bonding method of claim 1 wherein the fixture enhancement structure is selected from two or more of the group consisting of a curved surface refracting the UV radiation field towards each the target zone and away from portions of the bonding well not in the target zone, an external surface reflecting the UV radiation field towards each the target zone and away from portions of the bonding well not in the target zone, an internal surface reflecting the UV radiation field towards each the target zone and away from portions of the bonding well not in the target zone, a roughened external surface attenuating the UV radiation field relative to the target zone, a polished external surface transmitting the UV radiation field towards the target zone, and combinations thereof.

4 . The enhanced bonding method of claim 1 wherein the module fixture is a molded plastic structure made using a mold and a molding process.

5 . The enhanced bonding method of claim 4 wherein the fixture enhancement structure is defined by the mold.

6 . The enhanced bonding method of claim 1 wherein the fixture enhancement structure includes a curved surface refracting the UV radiation field towards each the target zone and away from portions of the bonding well not in the target zone.

7 . The enhanced bonding method of claim 1 wherein the fixture enhancement structure includes an external surface reflecting the UV radiation field towards each the target zone and away from portions of the bonding well not in the target zone.

8 . The enhanced bonding method of claim 1 wherein the fixture enhancement structure includes an internal surface reflecting the UV radiation field towards each the target zone and away from portions of the bonding well not in the target zone.

9 . The enhanced bonding method of claim 1 wherein the fixture enhancement structure includes a roughened external surface attenuating the UV radiation field relative to the target zone.

10 . The enhanced bonding method of claim 1 wherein the fixture enhancement structure includes a polished external surface transmitting the UV radiation field towards the target zone.

Assignees

• Tesla Motors Inc

Inventors

• Hachtmann Brian Dean
• Riegel Mark
• Hegeman David Elias
• Bishop Wiliam Christopher
• Beecher William Vucich

Classifications

• B29C35/0894 Primary

  provided with masks or diaphragms · CPC title

• H01M50/264

  for cells or batteries, e.g. straps, tie rods or peripheral frames · CPC title

• H01M50/227

  Organic material · CPC title

• B29C66/5324

  said single elements being substantially annular, i.e. of finite length (B29C66/5326 takes precedence) · CPC title

• B29L2031/3468

  Batteries, accumulators or fuel cells (battery cases B29L2031/7146) · CPC title