Battery module with heat-conducting pad member, and preparation method and overflow glue removing method thereof

Abstract

This invention discloses a battery module with a thermally conductive pad, its preparation method, and a method for removing excess adhesive. It belongs to the industrial field of battery module products with buffer pads and thermally conductive structural adhesive. The module includes a battery module, a liquid cooling plate, and a thermally conductive pad. The thermally conductive pad is mounted on the liquid cooling plate, and the battery module is mounted on the thermally conductive pad. The thermally conductive pad connects the bottom surface of the battery module to the liquid cooling plate as a single unit. Liquid cooling pipes connect the liquid cooling plates at the bottoms of adjacent battery modules. The thermally conductive pad contains a porous foam pad and a thermally conductive structural adhesive, with the adhesive filling the pores of the porous foam pad. This invention solves the problems of high cost of existing thermally conductive pads and the tendency for excess adhesive and uneven application using ordinary adhesive application methods. This thermally conductive pad optimizes and improves the thermal management of the bottom surface of the battery module compared to existing thermally conductive pads, while also offering advantages such as low cost, good thermal conductivity, reduced excess adhesive, and uniform adhesive application.

Description

Technical Field

[0001] This invention relates to battery module products with buffer pads and thermally conductive structural adhesive, and their preparation methods, as well as methods for removing excess adhesive during the preparation of such battery module products. In particular, it relates to battery modules with thermally conductive pads, their preparation methods, and methods for removing excess adhesive. Background Technology

[0002] With the increasing popularity of electric vehicles, accidents or malfunctions caused by abnormal battery temperatures occur frequently. Therefore, the manufacturing of electric vehicles places increasingly higher demands on the battery module products and their corresponding thermal management components. Currently, liquid cooling is the most common thermal management method for battery module systems in the battery industry. This method uses water flow in liquid cooling pipes to remove the heat generated during the operation of the battery module system, or to heat the battery module system at low temperatures, ensuring the overall stable and reliable operation of the battery module system.

[0003] In existing liquid-cooled thermal management systems for battery modules, the battery module system and liquid cooling pipelines are typically connected via thermally conductive pads or thermally conductive structural adhesives for heat exchange. While the advantages of using ordinary thermally conductive pads are their simple structure and ease of application, their disadvantages include high price and manufacturing costs, hindering cost reduction. The advantage of using ordinary thermally conductive adhesives is their lower price, which helps reduce the cost of battery module systems; however, ordinary adhesive application methods suffer from defects such as adhesive overflow and uneven application. Therefore, we propose a battery module with a thermally conductive pad, its fabrication method, and an adhesive overflow removal method. The thermally conductive pad fabricated using this method integrates a buffer pad and thermally conductive structural adhesive, allowing it to be connected to the liquid cooling plate. This can be used as a thermal management product in the manufacture of new battery module systems. The fabrication method of the battery module with the thermally conductive pad and the adhesive overflow removal method during the fabrication process are also described. Summary of the Invention

[0004] The purpose of this invention is to solve the problems of high cost of existing thermal pads and the tendency for glue overflow and uneven coating in ordinary adhesive application methods. This invention proposes a battery module with a thermal pad and its manufacturing method, and also provides a method for removing glue overflow during the manufacturing of battery modules with thermal pads. The thermal pad provided by this invention optimizes and improves the thermal management of the bottom surface of battery modules using existing thermal pads, while also offering advantages such as low cost, good thermal conductivity, less glue overflow, and uniform coating. It is suitable for widespread use in the production of battery modules as a thermal pad with buffer pads and thermally conductive structural adhesive, and also suitable for use as a method for removing glue overflow in the manufacturing of battery modules with thermal pads, demonstrating promising application prospects.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A battery module with a thermally conductive pad includes a battery module and a thermal management system located at the bottom of the battery module. The thermal management system includes a liquid cooling plate and liquid cooling pipes. The liquid cooling plate is disposed at the bottom of the battery module, and the liquid cooling pipes allow the liquid cooling plates at the bottom of adjacent battery modules to be interconnected. The module also includes:

[0007] The thermal management system includes a thermally conductive pad. A thermally conductive pad is mounted on the liquid cooling plate, and a battery module is mounted on the thermally conductive pad. The thermally conductive pad connects the bottom surface of the battery module to the liquid cooling plate as a single unit. This thermally conductive pad can replace ordinary thermally conductive pads, offering better thermal conductivity. While ensuring excellent heat transfer performance between the bottom surface of the battery module and the liquid cooling plate, the thermally conductive pad improves the tightness and stability of the connection between them.

[0008] The described thermal pad is a structural component that integrates a buffer pad and thermally conductive structural adhesive into one piece. Compared with ordinary thermal pads, it has the advantages of lower price, higher manufacturing efficiency, and better adhesive uniformity. Compared with ordinary thermally conductive adhesive, it avoids adhesive overflow and provides better adhesive uniformity.

[0009] The thermally conductive pad can be a thermally conductive structural adhesive layer, which can reduce the cost of the thermally conductive pad.

[0010] To improve the uniformity of the thermally conductive structural adhesive application and ensure a tight bond between the upper part of the thermal pad and the bottom surface of the battery module, further enhancing the adhesion between the bottom surface of the thermal pad and the liquid cooling plate, the thermal pad incorporates a porous gasket and thermally conductive structural adhesive. The thermally conductive structural adhesive fills the pores of the porous gasket. The porous gasket improves the uniformity of the thermally conductive structural adhesive application, increases the contact area between the thermally conductive structural adhesive and the porous gasket, ensuring a tight bond between the upper part of the thermal pad and the bottom surface of the battery module, further enhancing the adhesion between the bottom surface of the thermal pad and the liquid cooling plate, improving the bonding stability between the bottom surface of the thermal pad and the liquid cooling plate, effectively preventing localized detachment between the bottom surface of the battery module and the ordinary thermal pad, and also avoiding localized delamination between the ordinary thermal pad and the liquid cooling plate.

[0011] To improve the overall cushioning performance of the thermally conductive pad and prevent the thermally conductive adhesive from overflowing into the porous pad, further enhancing the overall anti-overflow performance of the porous pad, the porous pad can be a porous foam pad or a porous buffer pad. Porous foam pads or porous buffer pads can improve the overall cushioning performance of the thermally conductive pad, ensuring good overall cushioning performance between the bottom surface of the battery module and the liquid cooling plate.

[0012] The porous gasket has a grid-like pore structure inside and a pore wall structure that separates the grid-like pores. The grid-like pores and the pore wall structure that separates the grid-like pores are interconnected. The grid-like pores allow the downward pressure on the thermal pad to be evenly distributed when the battery module is pressed onto the thermal pad, ensuring that the thermally conductive adhesive can penetrate more fully into the pores of the porous gasket, resulting in better uniformity of the thermally conductive adhesive on the porous gasket. The pore wall structure that separates the grid-like pores prevents the thermally conductive adhesive from overflowing from the porous gasket, improving the overall anti-overflow performance of the porous gasket.

[0013] To ensure that the overall performance of the porous buffer pad meets the design requirements and to reduce the cost of the porous buffer pad, the porous buffer pad can be further made of foam. The foam can serve as a porous buffer pad, which can reduce the cost of the porous buffer pad while ensuring that the overall performance of the porous buffer pad meets the design requirements.

[0014] A method for fabricating a battery module with a thermally conductive pad includes the following steps:

[0015] The first step is to place the battery module to be installed with the liquid cooling plate and thermal pad on the corresponding tooling tray and accurately position it;

[0016] The second step is to attach and fix the porous gasket used to prepare the thermally conductive pad onto the liquid cooling plate.

[0017] The third step is to place the liquid cooling plate with the porous gasket attached on the corresponding station of the glue applicator.

[0018] The fourth step is to start the automatic robotic arm of the glue applicator and apply the thermally conductive structural adhesive to the porous gaskets on the liquid cooling plate with the porous gaskets attached.

[0019] Fifth step: Place the liquid cooling plate with thermally conductive structural adhesive applied to the porous gasket into the corresponding heating fixture;

[0020] The sixth step involves hoisting the battery module onto the liquid cooling plate within the heating fixture from the fifth step. Specifically, the battery module is hoisted and placed above the liquid cooling plate on which thermally conductive structural adhesive has been applied to a porous pad. The weight of the battery module itself applies pressure to the thermally conductive structural adhesive applied to the porous pad, ensuring that the adhesive fully fills the porous pores of the pad. This allows the bottom surface of the battery module to maintain full contact with the liquid cooling plate through the thermally conductive structural adhesive and the porous pad. During this process, the thermally conductive structural adhesive flows and fills the porous pores within the porous pad, without overflowing the pore wall structure that separates the grid-like pores around the perimeter of the pad.

[0021] Step 7: Turn on the heating fixture to enable it to start automatic heating.

[0022] Step 8: After the heating fixture finishes its automatic heating process, a battery module product with a thermally conductive pad is produced. The battery module product with the thermally conductive pad is then lifted off the heating fixture by a hoisting machine. The battery module product with the thermally conductive pad is now complete and off the production line.

[0023] Pre-prepared thermal pads can be placed between the bottom of the battery module and the liquid cooling plate to produce battery module products with thermal pads. This saves on the adhesive coating equipment and labor input required to prepare the thermal pads.

[0024] However, when manufacturing battery module products with thermal pads, the battery module needs to be assembled on top of the pre-prepared thermal pads and pressurized so that the thermally conductive structural adhesive inside the pre-prepared thermal pads can fully fill the porous pores of the buffer pads. This ensures that the bottom surface of the battery module can maintain sufficient and uniform contact with the liquid cooling plate, eliminating defects caused by the flatness tolerance of the bottom surface of the battery module and the flatness of the top surface of the liquid cooling plate.

[0025] Meanwhile, the porous pad used to prepare the thermally conductive pad can be a porous buffer pad. The porous buffer pad has a grid-like pores and a pore wall structure that can separate the grid-like pores. At this time, since the thermally conductive structural adhesive has a certain viscosity, when the thermally conductive structural adhesive applied to the porous buffer pad is subjected to the downward pressure provided by the weight of the battery module, the thermally conductive structural adhesive can flow inside the porous buffer pad and fill the grid-like pores inside the porous buffer pad, but will not cross the pore wall structure that separates the grid-like pores. This ensures that the thermally conductive structural adhesive will not overflow beyond the vertical projection area of ​​the bottom surface of the battery module on the liquid cooling plate.

[0026] To reduce the cost of the thermal pad, the thermal pad is further defined as a thermally conductive structural adhesive layer. The thermally conductive structural adhesive layer, as a thermal pad, can reduce the cost of the thermal pad. A method for preparing a battery module with a thermally conductive structural adhesive layer and a method for removing excess adhesive are provided, including the following steps:

[0027] The first step is to place the battery module with the liquid cooling plate and thermally conductive adhesive layer to be installed on the corresponding tooling tray and accurately position it;

[0028] The second step is to place the liquid cooling plate as a whole on the corresponding station of the glue applicator;

[0029] The fourth step is to start the automatic robotic arm of the glue applicator and apply the thermally conductive structural adhesive for making the thermally conductive structural adhesive layer to the glue application area on the liquid cooling plate.

[0030] Fifth step: Apply PET film around the area where the battery module will be placed inside the heating fixture;

[0031] Step 6: Place the liquid cooling plate with the thermally conductive structural adhesive applied in the adhesive area on the liquid cooling plate into the heating fixture corresponding to Step 5, so that the PET film blocks the liquid cooling plate around its perimeter. Then, lift the battery module onto the liquid cooling plate in the heating fixture, so that the PET film covers the battery module around its perimeter, allowing the overflowing thermally conductive structural adhesive to enter the PET blue film instead of the heating fixture.

[0032] Step 7: Turn on the heating fixture to enable it to start automatic heating.

[0033] Step 8: After the heating fixture finishes its automatic heating process, a battery module product with a thermally conductive adhesive layer is produced. A hoisting machine is used to lift the battery module product with the thermally conductive adhesive layer from the heating fixture after the heating process is completed. The PET film is then manually removed, and the thermally conductive adhesive that has overflowed around the bottom of the battery module or the edge of the liquid cooling plate is cleaned. After the removal is completed, the overflow adhesive removal is finished, and the battery module product with the thermally conductive adhesive layer is completed and off the production line.

[0034] Because the thermally conductive structural adhesive, when applied to the liquid cooling plate, is prone to overflow or uneven application when subjected to downward pressure from the weight of the battery module, a PET film is first applied around the area where the battery module is to be placed inside the heating fixture. This allows the adhesive overflowing from the liquid cooling plate under pressure to enter the PET film instead of the heating fixture. After the automatic heating process is completed, the battery module with the thermally conductive structural adhesive layer is lifted out of the heating fixture by a hoisting machine. Then, the PET film is manually removed, and any thermally conductive structural adhesive overflowing around the bottom of the battery module or the edge of the liquid cooling plate is cleaned.

[0035] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0036] 1. A battery module with a thermally conductive pad is used, wherein the thermal management system solution with the thermally conductive pad can replace the thermal management system of ordinary thermally conductive pad and ordinary thermally conductive adhesive. The thermally conductive pad in this invention can connect the bottom surface of the battery module to the liquid cooling plate as one unit. The thermally conductive pad has good thermal conductivity. Under the condition of ensuring excellent heat transfer performance between the bottom surface of the battery module and the liquid cooling plate, the thermally conductive pad can improve the tightness and stability of the connection between the bottom surface of the battery module and the liquid cooling plate.

[0037] 2. The method for preparing a battery module with a thermally conductive adhesive layer and the method for removing excess adhesive provided by this invention can solve the problem of excess adhesive and remove excess adhesive compared with ordinary adhesive coating methods, which is conducive to improving production efficiency and reducing costs.

[0038] 3. The main body of the thermally conductive pad of the present invention is a low-cost porous pad and a thermally conductive structural adhesive. Compared with the expensive traditional thermally conductive pad solution, the present invention integrates the reduction of material costs and simplification of the manufacturing process, which can significantly reduce the overall manufacturing cost.

[0039] 4. The battery module in this invention can be a non-standard battery module of the 2P18S model. At the same time, the battery module in this invention can also be replaced by other battery modules of suitable size or type that require thermal management system fabrication at the bottom.

[0040] 5. The thermal pad of the present invention is made of a porous pad with internal grid-like pores and a pore wall structure that separates the grid-like pores, and a matching thermally conductive structural adhesive. The grid-like pores allow the downward pressure on the thermal pad to be evenly distributed when the battery module is pressed onto the thermal pad, ensuring that the thermally conductive structural adhesive can penetrate more fully into the pores of the porous pad, resulting in better uniformity of the thermally conductive structural adhesive on the porous pad. The pore wall structure that separates the grid-like pores prevents the thermally conductive structural adhesive from overflowing from the porous pad, thus improving the overall anti-overflow performance of the thermal pad.

[0041] 6. The thermal conductive pad in this invention is a structural component that integrates a buffer pad and a thermally conductive structural adhesive into one piece. Compared with ordinary thermal conductive pads, the thermal conductive pad has the advantages of low price, high manufacturing efficiency, and good adhesive uniformity. Compared with ordinary thermally conductive adhesive, the thermal conductive pad has the advantages of avoiding adhesive overflow and good adhesive uniformity. Attached Figure Description

[0042] Figure 1 This is a schematic diagram of the overall structure of the battery module with a thermally conductive pad in this invention;

[0043] Figure 2 This is an enlarged schematic diagram of region A in the overall structure of the battery module with thermal pad in this invention;

[0044] Figure 3 This is a schematic diagram of the overall structure of the thermal management system component after the thermally conductive pad and the liquid cooling plate are integrated.

[0045] Figure 4 This is a perspective view of the overall structure of the thermal management system component after the thermally conductive pad and the liquid cooling plate are integrated.

[0046] Figure 5 This is a schematic diagram of the overall structure of the thermally conductive pad after the thermally conductive structural adhesive of the present invention is applied to a porous pad and pressed down to form a thermally conductive pad.

[0047] Figure 6 This is a front view of the longitudinal section of the thermally conductive pad after the thermally conductive structural adhesive of the present invention is applied to a porous pad and pressed down to form a thermally conductive pad.

[0048] Figure 7 When the thermal pad is a structural component that integrates a buffer pad and a thermally conductive structural adhesive, and the thermal pad is connected to the liquid cooling plate, the following is a schematic diagram of the assembly and connection between the battery module and the thermal pad in this invention.

[0049] Figure 8 This is a schematic diagram of the assembly and connection of the battery module and the liquid cooling plate thermal management system components in the conventional adhesive coating method compared with the present invention.

[0050] In the diagram: 1. Battery module; 2. Thermal pad; 21. Porous gasket; 22. Thermally conductive structural adhesive; 3. Thermal pad; 31. Liquid cooling groove passage; 32. Circulation pipe connector; 4. Adhesive application area. Detailed Implementation

[0051] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0052] In the description of this invention, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0053] The present invention will be further described in detail below with reference to embodiments and specific implementation methods.

[0054] Reference Figure 1 、 Figure 2 、 Figure 3 、 Figure 4 、 Figure 5 、 Figure 6 、 Figure 7 and Figure 8 A battery module with a thermally conductive pad includes a battery module 1 and a thermal management system located at the bottom of the battery module. The thermal management system includes a liquid cooling plate 3 and liquid cooling pipes. The liquid cooling plate 3 is located at the bottom of the battery module 1. The liquid cooling pipes allow adjacent liquid cooling plates 3 at the bottom of different battery modules 1 to be interconnected. The liquid cooling plate 3 is provided with a circulation pipe connector 32, which allows adjacent liquid cooling plates 3 at the bottom of different battery modules 1 to be interconnected via the liquid cooling pipes. The liquid cooling plate 3 has a liquid cooling groove passage 31 inside, allowing the liquid cooling material to circulate within the liquid cooling groove passage 31 inside the liquid cooling plate 3 (e.g., Figure 4 (As shown), it also includes:

[0055] The thermal management system includes a thermally conductive pad 2, and the liquid cooling plate 3 is provided with a thermally conductive pad 2 (e.g. Figure 3 and Figure 4 As shown), the thermal pad 2 has a battery module 1 mounted on it, and the thermal pad 2 can connect the bottom surface of the battery module 1 to the liquid cooling plate 3 as a whole (as shown). Figure 1 As shown, the thermal pad 2 can replace the ordinary thermal pad, and has a better thermal conductivity. The thermal pad 2 can improve the tightness and stability of the connection between the bottom surface of the battery module 1 and the liquid cooling plate 3 while ensuring excellent heat transfer performance.

[0056] The thermally conductive pad 2 is a structural component that integrates a buffer pad and thermally conductive structural adhesive 22 into one piece. Compared with ordinary thermally conductive pads, the thermally conductive pad 2 has the advantages of lower price, higher manufacturing efficiency, and better adhesive uniformity. Compared with ordinary thermally conductive adhesive, the thermally conductive pad 2 has the advantages of avoiding adhesive overflow and ensuring better adhesive uniformity.

[0057] The thermally conductive pad 2 can be a thermally conductive structural adhesive layer, which can reduce the cost of the thermally conductive pad 2.

[0058] To improve the uniformity of the thermally conductive structural adhesive 22 application, ensure a tight bond between the upper part of the thermally conductive pad 2 and the bottom surface of the battery module 1, and guarantee a better adhesion between the bottom surface of the thermally conductive pad 2 and the liquid cooling plate 3, the thermally conductive pad 2 has a porous gasket 21 and thermally conductive structural adhesive 22 (such as...). Figure 5 and Figure 6 As shown), the thermally conductive structural adhesive 22 fills the pores of the porous pad 21. The porous pad 21 can improve the uniformity of the thermally conductive structural adhesive 22 coating, increase the contact area between the thermally conductive structural adhesive 22 and the porous pad 21, and make the upper part of the thermally conductive pad 2 and the bottom surface of the battery module 1 tightly bonded. This ensures that the bottom surface of the thermally conductive pad 2 is more bonded to the liquid cooling plate 3, improves the bonding stability between the bottom surface of the thermally conductive pad 2 and the liquid cooling plate 3, and can effectively prevent the bottom surface of the battery module 1 from partially detaching from the ordinary thermally conductive pad. It can also avoid partial detachment between the ordinary thermally conductive pad and the liquid cooling plate 3.

[0059] To improve the overall cushioning performance of the thermally conductive pad 2 and prevent the thermally conductive structural adhesive 22 from overflowing from the porous pad 21, thus enhancing the overall anti-overflow performance of the porous pad 21, the porous pad 21 can be a porous foam pad or a porous buffer pad. A porous foam pad or a porous buffer pad can improve the overall cushioning performance of the thermally conductive pad 2, ensuring good overall cushioning performance between the bottom surface of the battery module 1 and the liquid cooling plate 3.

[0060] The porous pad 21 has a grid-like pore structure inside and a pore wall structure that can separate the grid-like pores. The grid-like pores and the pore wall structure that separates the grid-like pores are connected to each other. The grid-like pores can make the downward pressure on the thermal pad 2 uniformly distributed when the battery module 1 is pressed onto the thermal pad 2, ensuring that the thermally conductive adhesive 22 can penetrate more fully into the pores of the porous pad 21, making the thermally conductive adhesive 22 more uniformly dispersed on the porous pad 21. The pore wall structure that separates the grid-like pores can make the thermally conductive adhesive 22 less likely to overflow from the porous pad 21, improving the overall anti-overflow performance of the porous pad 21.

[0061] To ensure that the overall performance of the porous buffer pad meets the design requirements and to reduce the cost of the porous buffer pad, the porous buffer pad can be made of foam. The foam can be used as a porous buffer pad, which can reduce the cost of the porous buffer pad while ensuring that the overall performance of the porous buffer pad meets the design requirements.

[0062] The method for preparing a battery module 1 having a thermally conductive pad 2 includes the following steps:

[0063] The first step is to place the battery module 1, which is to be installed with the liquid cooling plate 3 and the thermal pad 2, on the corresponding tooling tray and accurately position it;

[0064] The second step is to attach and fix the porous gasket 21 of the prepared thermal pad 2 onto the liquid cooling plate 3.

[0065] The third step is to place the liquid cooling plate 3 with the porous gasket 21 attached on the corresponding station of the glue applicator.

[0066] The fourth step is to start the automatic robotic arm of the glue applicator and apply the thermally conductive structural adhesive 22 to the porous gasket 21 on the liquid cooling plate 3 on which the porous gasket 21 is attached.

[0067] Fifth step, place the liquid cooling plate 3 with thermally conductive structural adhesive 22 applied to the porous gasket 21 into the corresponding heating fixture;

[0068] The sixth step involves hoisting the battery module 1 onto the liquid cooling plate 3 within the heating fixture of the fifth step. Specifically, the battery module 1 is hoisted and placed above the liquid cooling plate 3 on which thermally conductive structural adhesive 22 is applied to the porous pad 21. The weight of the battery module 1 applies pressure to the thermally conductive structural adhesive 22 applied to the porous pad 21, ensuring that the thermally conductive structural adhesive 22 fully fills the porous pores of the porous pad 21. This allows the bottom surface of the battery module 1 to maintain full contact with the liquid cooling plate 3 through the thermally conductive structural adhesive 22 and the porous pad 21. During this process, the thermally conductive structural adhesive 22 flows and fills the porous pores inside the porous pad 21, without overflowing the pore wall structure around the perimeter of the porous pad 21 that separates the grid-like pores.

[0069] Step 7: Turn on the heating fixture to enable it to start automatic heating.

[0070] Step 8: After the heating fixture finishes its automatic heating process, a battery module 1 product with a thermally conductive pad 2 is produced. The battery module 1 product with the thermally conductive pad 2 is then lifted off the heating fixture by a hoisting machine. The battery module 1 product with the thermally conductive pad 2 is now complete and off the production line.

[0071] A pre-prepared thermal pad 2 can be placed between the bottom surface of the battery module 1 and the liquid cooling plate 3 to produce a battery module 1 product with a thermal pad 2. In this case, the adhesive coating equipment and labor input for preparing the thermal pad 2 can be saved.

[0072] However, when manufacturing a battery module product with a thermally conductive pad 2, the battery module 1 needs to be mounted on top of the pre-prepared thermally conductive pad 2 and pressurized so that the thermally conductive structural adhesive 22 inside the pre-prepared thermally conductive pad 2 can fully fill the porous pores of the buffer pad, ensuring that the bottom surface of the battery module 1 can maintain sufficient and uniform contact with the liquid cooling plate 3, eliminating the defects of insufficient contact caused by the tolerance of the flatness of the bottom surface of the battery module 1 and the flatness of the top surface of the liquid cooling plate 3;

[0073] Meanwhile, the porous pad 21 used to prepare the thermally conductive pad 2 can be a porous buffer pad. The porous buffer pad has a grid-like pores and a pore wall structure that can separate the grid-like pores. At this time, since the thermally conductive structural adhesive 22 has a certain viscosity, when the thermally conductive structural adhesive 22 applied to the porous buffer pad is subjected to the downward pressure provided by the weight of the battery module 1, the thermally conductive structural adhesive 22 can flow inside the porous buffer pad and fill the grid-like pores inside the porous buffer pad, but will not cross the pore wall structure that separates the grid-like pores, thereby ensuring that the thermally conductive structural adhesive 22 will not overflow beyond the vertical projection area of ​​the bottom surface of the battery module 1 on the liquid cooling plate 3.

[0074] To reduce the cost of the thermal pad 2, the thermal pad 2 is a thermally conductive structural adhesive layer. The thermally conductive structural adhesive layer, as the thermal pad 2, can reduce the cost of the thermal pad 2. The method for preparing a battery module with a thermally conductive structural adhesive layer and the method for removing excess adhesive include the following steps:

[0075] The first step is to place the battery module 1, which has the liquid cooling plate 3 and the thermally conductive adhesive layer to be installed, on the corresponding tooling tray and accurately position it;

[0076] The second step is to place the liquid cooling plate 3 as a whole on the corresponding station of the glue applicator;

[0077] The fourth step is to start the automatic robotic arm of the glue applicator and apply the thermally conductive structural adhesive 22, which is used to make the thermally conductive structural adhesive layer, to the glue application area 4 on the liquid cooling plate 3.

[0078] Step 5: Apply PET film around the area where battery module 1 will be placed inside the heating fixture;

[0079] Step 6: Place the liquid cooling plate 3 with the thermally conductive structural adhesive 22 applied in the adhesive area 4 on the liquid cooling plate 3 into the heating fixture corresponding to the step 5, so that the PET film blocks the liquid cooling plate 3 around its perimeter. Then, hoist the battery module 1 onto the liquid cooling plate 3 in the heating fixture, so that the PET film covers the battery module 1 around its perimeter, allowing the overflowing thermally conductive structural adhesive 22 to enter the PET blue film instead of the heating fixture.

[0080] Step 7: Turn on the heating fixture to enable it to start automatic heating.

[0081] Step 8: After the heating fixture finishes its automatic heating process, a battery module 1 product with a thermally conductive adhesive layer is produced. The battery module 1 product with the thermally conductive adhesive layer is lifted out of the heating fixture after the heating process is completed using a hoisting machine. The PET film is then manually removed, and the thermally conductive adhesive 22 that has overflowed around the lower part of the battery module 1 or the upper edge of the liquid cooling plate 3 is removed. After the removal is completed, the overflow adhesive removal is finished, and the battery module 1 product with the thermally conductive adhesive layer is completed and off the production line.

[0082] During this process, after the thermally conductive structural adhesive 22 is applied to the liquid cooling plate 3, it is easy to cause problems such as adhesive overflow or uneven application when subjected to the downward pressure provided by the weight of the battery module 1. To solve this, PET film is first attached around the area where the battery module 1 is to be placed inside the heating fixture. This allows the adhesive overflowing from the liquid cooling plate 3 under pressure to enter the PET blue film instead of the heating fixture. After the automatic heating is completed, the battery module 1 with the thermally conductive structural adhesive layer is lifted out of the heating fixture by the hoisting machine. Then, the PET blue film is manually removed by personnel, and the thermally conductive structural adhesive 22 overflowing around the lower part of the battery module 1 or the upper edge of the liquid cooling plate 3 is cleaned.

[0083] This invention addresses the problems of high cost and uneven adhesive application caused by conventional thermal pads. It proposes a battery module with a thermal pad component 2 and its manufacturing method, and also provides a method for removing excess adhesive during the manufacturing of the battery module with the thermal pad component 2. The thermal pad component 2 provided by this invention optimizes and improves the thermal management of the bottom surface of the battery module 1 compared to conventional thermal pads. It combines the advantages of low cost, good thermal conductivity, minimal adhesive overflow, and uniform adhesive application. It is suitable for widespread use in the production of battery module 1 as a thermal pad component 2 with a buffer pad and thermally conductive structural adhesive 22, and is also suitable for widespread use as a method for removing excess adhesive in the manufacturing of battery module 1 with the thermal pad component 2, demonstrating promising application prospects.

[0084] The above are merely preferred embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A method for preparing a battery module with a thermally conductive pad, characterized in that: Includes the following steps: The first step is to place the battery module to be installed with the liquid cooling plate and thermal pad on the corresponding tooling tray and accurately position it; The second step is to attach and fix the porous gasket used to prepare the thermally conductive pad onto the liquid cooling plate. The porous gasket has a gridded pore interior and a pore wall structure that separates the gridded pores, and the gridded pores and the pore wall structure that separates the gridded pores are connected to each other. The third step is to place the liquid cooling plate with the porous gasket attached on the corresponding station of the glue applicator. The fourth step is to start the automatic robotic arm of the glue applicator and apply the thermally conductive structural adhesive to the porous gaskets on the liquid cooling plate with the porous gaskets attached. Fifth step: Place the liquid cooling plate with thermally conductive structural adhesive applied to the porous gasket into the corresponding heating fixture; The sixth step involves hoisting the battery module onto the liquid cooling plate within the heating fixture from the fifth step. Specifically, the battery module is hoisted and placed above the liquid cooling plate on which thermally conductive structural adhesive has been applied to a porous pad. The weight of the battery module itself applies pressure to the thermally conductive structural adhesive applied to the porous pad, ensuring that the adhesive fully fills the porous pores of the pad. This allows the bottom surface of the battery module to maintain full contact with the liquid cooling plate through the thermally conductive structural adhesive and the porous pad. During this process, the thermally conductive structural adhesive flows and fills the porous pores within the porous pad, without overflowing the pore wall structure that separates the grid-like pores around the perimeter of the pad. Step 7: Turn on the heating fixture to enable it to start automatic heating. Step 8: After the heating fixture finishes its automatic heating process, a battery module product with a thermally conductive pad is produced. The battery module product with the thermally conductive pad is then lifted off the heating fixture using a hoisting machine. The battery module product with the thermally conductive pad is now complete and off the production line.

2. The method for preparing a battery module with a thermally conductive pad according to claim 1, characterized in that, The porous gasket is a foam component.

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