Patent ID: 8057630

Claim:
A bonding method, the method comprising the steps of: (a) dispensing a high-wettability adhesive into a first module fixture populated with a plurality of elements wherein said first module fixture provides a plurality of bonding wells with each bonding well accepting a first portion of one or more of said elements with said module fixture including one more apertures communicated with one or more of said bonding wells, said adhesive being selectively curable upon application of a curing modality; (b) applying said curing modality selectively to a first portion of said dispensed adhesive in a seal zone, said seal zone including one or more regions surrounding said apertures wherein said dispensed adhesive in said seal zone is sufficiently cured to inhibit significant quantities of said adhesive from emerging from said apertures while said adhesive continues to be dispensed into said module fixture wherein said curing modality is not applied to a second portion of said adhesive outside of said seal zone; and (c) applying said curing modality to said second portion of said dispensed adhesive, wherein said dispensed adhesive includes a plurality of wettability characteristics during dispensing with said first portion of said adhesive having a different wettability than said second portion of said adhesive, and wherein said module fixture includes a first battery fixture clamshell and a second battery fixture clamshell, said plurality of elements include a plurality of battery cells, said bonding wells formed from counterbores in said clamshells with said portions of said batteries accepted within said counterbores including an end of said battery cell and wherein each counterbore populated with an end of one of said battery cells has a portion of a wall of said clamshell defining a contact port aperture communicated to said counterbore allowing electrical communication to said end of said battery cell from outside said clamshell.