Temperature gradient control with variations in the thermal interface material

Abstract

Battery module (100) comprising: a cooling surface (112) comprising a first area (112a) and a second area (112b), wherein the first area (112a) and the second area (112b) have different cooling capacities; an adhesive (108) comprising a first component with a first thermal conductivity and a second component with a second thermal conductivity;and a first battery cell (102) and a second battery cell (102), wherein: a first end (104) of the first battery cell (102) is attached to the first region (112a) by a first section of the adhesive (108) and a first end (104) of the second battery cell (102) is attached to the second region (112b) by a second section of the adhesive (108), the first section of the adhesive (108) has a first ratio (108a) of the first component to the second component and the second section of the adhesive (108) has a second ratio (108b) of the first component to the second component, and the first ratio (108a) and the second ratio (108b) are different and compensate for the different cooling capacities of the first region (112a) and the second region (112b).

Description

SHORT STORY

[0001] It is advantageous to pack battery cells tightly in large-format, high-voltage battery modules to provide high-energy-density battery modules. To achieve a high-energy-density battery module, cylindrical battery cells can be arranged, with the lower end of each cell attached to a cooling surface of the battery module using an adhesive. However, in such battery modules, the temperature gradient across the numerous battery cells must be effectively controlled to ensure uniform cooling of all cells.

[0002] Therefore, it is advantageous if the cooling capacity of the cooling surface is evenly distributed across the surface. If the cooling capacity varies across the surface and the temperature gradient across the multitude of battery cells is not effectively controlled, certain cells will be cooled less than others in the battery module and will degrade faster, leading to accelerated power loss for the entire module. Furthermore, if the temperature gradient across the multitude of battery cells is not effectively controlled, it can be difficult to estimate the temperature of each cell in the battery module during operation (e.g., by measuring the temperature of selected cells and estimating the temperature of the others based on the measured temperatures) without directly measuring the temperature of each cell.

[0003] These problems can be particularly relevant in large-format battery modules with multiple arrays of battery cells electrically connected in parallel groups, because temperature sensors for many or all battery cells can cause additional costs and complexity, and because the power loss of a single battery cell in a parallel group of battery cells can spread to all battery cells in the parallel group of battery cells, significantly reducing the performance of the battery module.

[0004] To solve these problems, systems and methods for efficiently controlling the temperature gradient across a large number of battery cells in a battery module (e.g., a high-energy-density battery module) are provided herein. To achieve this, a battery module and a method for assembling the battery module are provided. The battery module includes a cooling surface comprising a first region and a second region, each with different cooling capacities; an adhesive comprising a first component with a first thermal conductivity and a second component with a second thermal conductivity; and a first battery and a second battery. A first end of the first battery is attached to the first region by a first section of the adhesive, and a first end of the second battery is attached to the second region by a second section of the adhesive.The first section of the adhesive has a first ratio of the first component to the second component, and the second section of the adhesive has a second ratio of the first component to the second component. These first and second ratios are different and compensate for the different cooling capacities of the first and second sections.

[0005] In some embodiments of the present disclosure, each of the first component and the second component may be a resin, and the adhesive may further include a hardener.

[0006] In some embodiments of the present disclosure, the battery module may further include a cooling plate. The cooling surface may form a first side of the cooling plate.

[0007] In some embodiments of the present disclosure, the cooling plate may further include an inlet port, an outlet port, and a cooling channel. Coolant may flow from the inlet port to the outlet port through the cooling channel.

[0008] In some embodiments of the present disclosure, the first area can have a first cooling capacity and the second area a second cooling capacity, the first cooling capacity can be greater than the second cooling capacity, the first thermal conductivity can be greater than the second thermal conductivity, the first ratio of the first component to the second component can be greater than the second ratio of the first component to the second component, and the first ratio and the second ratio can compensate for the difference between the first cooling capacity and the second cooling capacity, so that the same cooling capacity can be provided to the first battery and the second battery.

[0009] In some embodiments of the present disclosure, the first thermal conductivity may be greater than or equal to 1.0 watt / meter*kelvin (W / m*K), and the second thermal conductivity may be less than or equal to 0.3 W / m*K.

[0010] In some embodiments of the present disclosure, the adhesive may further include a plurality of ridges to space the first end of each of the first battery and the second battery at a predetermined distance from the cooling surface.

[0011] In some embodiments of the present disclosure, the cooling surface can be a first cooling surface, and the battery module can further include a second cooling surface opposite the first cooling surface. The second cooling surface can include a third region and a fourth region, wherein the third region and the fourth region can have different cooling capacities. The battery module can further include a third battery and a fourth battery.A first end of the third battery can be attached to the third area by a third section of the adhesive, a first end of the fourth battery can be attached to the fourth area by a fourth section of the adhesive, the third section can have a third ratio of the first component to the second component and the second section can have a fourth ratio of the first component to the second component, and the third ratio and the fourth ratio can be different and can compensate for the different cooling capacities of the third area and the fourth area, so that a similar cooling capacity can be provided to the third battery and the fourth battery.

[0012] In some embodiments of the present disclosure, the first ratio may be an average ratio of the first component to the second component of the first section, and a ratio of the first component to the second component of the first section may vary within the first range.

[0013] In some embodiments of the present disclosure, the first ratio within the first section may be constant.

[0014] In some embodiments, a method for assembling a battery module is provided.The method includes: providing a cooling surface with a cooling capacity that varies across the cooling surface; providing an adhesive comprising a first component with a first thermal conductivity to a second component with a second thermal conductivity; providing a first battery and a second battery; applying the adhesive with a first ratio of the first component to the second component to a first area of ​​the cooling surface; applying the adhesive with a second ratio of the first component to the second component to a second area of ​​the cooling surface; attaching a first end of the first battery to the first area using the adhesive applied to the first area; and attaching a first end of the second battery to the second area using the adhesive applied to the second area.The first ratio and the second ratio are different and compensate for the different cooling capacities of the first area and the second area. List of characters

[0015] The foregoing and other tasks and advantages of the present disclosure will become clear when considering the following detailed description in conjunction with the accompanying drawings, in which the same reference numerals consistently refer to the same parts and in which: Fig. 1 shows a view of a battery module according to some embodiments of the present disclosure; Fig. 2 shows a top view of a planned arrangement of battery cells on a first cooling surface of a cooling plate, according to some embodiments of the present disclosure; Fig. 3A shows a cross-sectional view through the center of an illustrative cooling plate according to some embodiments of the present disclosure; Fig. 3B shows an adhesive with different thermal conductivity applied to the first cooling surface of the illustrative cooling plate, according to some embodiments of the present disclosure; Fig. 4 shows a view of a battery module according to some embodiments of the present disclosure; Fig. 5 shows a block diagram of a device for mixing and arranging an adhesive on the first cooling surface of the cooling plate according to some embodiments of the present disclosure; and Fig. Figure 6 shows a flowchart of a method for manufacturing a battery module according to some embodiments of the present disclosure. DETAILED DESCRIPTION

[0016] In light of the foregoing and according to some embodiments of the present disclosure, it would be advantageous to provide a high-energy-density and easy-to-manufacture battery module that efficiently controls the temperature gradient across the plurality of battery cells in the battery module. In some embodiments, the battery module provided herein can utilize any cooling surface to provide uniform cooling, including the cooling surface of a cooling plate using liquid cooling. To achieve this, the battery module described herein can use an adhesive (e.g., a thermal interface material) with a variable coefficient of thermal expansion to bond each of the battery cells in the battery module to a cooling surface.By varying the thermal coefficient of the adhesive based on a cooling profile of the cooling surface, the adhesive can compensate for any differences in cooling performance across the cooling surface, thereby ensuring uniform cooling (or heating) of all battery cells in the battery module.

[0017] Fig. Figure 1 shows a view of a battery module 100 according to some embodiments of the present disclosure. As shown, the battery module 100 includes a plurality of battery cells 102. Each of the battery cells 102 can be cylindrical and have a first end 104 comprising a first electrical terminal and a second end 106 with a second electrical terminal 107 (e.g., a central button terminal). In some embodiments of the present disclosure, each of the battery cells 102 can have an exposed area of ​​an electrically active housing or a conductive sheath that covers at least a portion of the first end 104 and one side of each battery cell 102 and forms the first electrical terminal. To increase the packing density, the battery cells 102 can be arranged in rows that are offset from one another (e.g., in a hexagonal, densely packed arrangement).In some embodiments of the present disclosure, each adjacent pair of battery cells 102 can be 1.5 mm or less apart. Groups of battery cells 102 can be electrically connected in series or parallel using one or more busbars (not shown for simplicity). In some embodiments of the present disclosure, several battery cells 102 can be connected in parallel to form a subgroup, and a plurality of subgroups can be connected in series. In some embodiments of the present disclosure, the plurality of subgroups can be voltage-balanced with respect to one another. It is understood that there can be any suitable number of battery cells 102.

[0018] The battery module 100 can further include a heat transfer plate, e.g., a cooling plate 110, as shown. The cooling plate 110 can have a first cooling surface 112. As shown, the first end 104 of each of the battery cells 102 can be attached to the first cooling surface 112 by an adhesive 108. As described in more detail below, the adhesive 108 can be an adhesive with a variable heat transfer coefficient. In some embodiments of the present disclosure, the cooling plate 110 can be used for selectively cooling (or heating) the battery cells 102. In some embodiments of the present disclosure, the cooling plate 110 can have one or more channels through which cooling / heating fluid can flow, as described below with reference to Fig. 3A is described in more detail. In some embodiments of the present disclosure, the cooling plate 110 may be made of an electrically conductive material (e.g., a metal such as aluminum). In some embodiments of the present disclosure, the first cooling surface 112 may comprise a dielectric coating to reduce the probability of an electrical short circuit between the battery cells 102 and the first cooling surface 112. The cooling plate 110 may have a second cooling surface 114 opposite the first cooling surface 112, which may also comprise a dielectric coating.

[0019] Fig. Figure 2 shows a top view of a planned arrangement of the battery cells 102 on the first cooling surface 112 of the cooling plate 110, according to some embodiments of the present disclosure. For the sake of simplicity, a planned arrangement of four rows with five battery cells 102 per row is shown. However, it is understood that any suitable number of battery cells 102 in any arrangement is possible. As shown, the planned arrangement of the battery cells 102 can be located within a battery mounting area 202 of the first cooling surface 112.

[0020] Before the battery cells 102 are attached to the first cooling surface 112, a cooling profile of the first cooling surface 112 can be determined. The cooling profile of the first cooling surface 112 refers to the cooling performance provided at each point or localized area on the entire first cooling surface 112. In some embodiments of the present disclosure, the cooling profile of the first cooling surface 112 includes the entire area within the battery mounting area 202. In other embodiments of the present disclosure, the cooling profile of the first cooling surface 112 includes only those sections of the first cooling surface 112 that correspond to the planned arrangement of each of the battery cells 102 (i.e., 112a, 112b, 112c, 112d, 112e, ... 112n).

[0021] The cooling performance at any point on the entire first cooling surface 112 can vary based on a number of factors, including, for example, proximity to an edge of the cooling plate 110, proximity to a cooling channel (e.g., alignment / misalignment with the cooling channel) and the temperature of the coolant in the cooling channel, proximity to other devices mounted on the first cooling surface 112, and any other factors affecting the cooling performance. For example, the thickness of the total stack between the bottom of the battery cell 102 mounted on the first cooling surface 112 and the coolant in the cooling channel can also affect the cooling performance. In some embodiments of the present disclosure, the cooling profile of the first cooling surface 112 can be determined experimentally. For example, the cooling performance at any point on the first cooling surface 112 can be measured.In some embodiments of the present disclosure, the cooling profile of the first cooling surface 112 can be estimated by modeling the first cooling surface 112. In some embodiments of the present disclosure, the cooling profile of the first cooling surface 112 can be determined in advance and stored in a memory.

[0022] The resolution of the cooling profile of the first cooling surface 112 can vary depending on the application. In some embodiments of the present disclosure, the resolution of the cooling profile of the first cooling surface 112, as explained in more detail below, can correspond to the resolution at which the thermal coefficient of the adhesive can be changed (e.g., 1 mm). In some embodiments of the present disclosure, the cooling performance of each section (e.g., 1 mm x 1 mm) of the first cooling surface 112 can be determined to determine the cooling profile. In some embodiments of the present disclosure, the first cooling profile of the first cooling surface 112 can include the average cooling performance of each of the sections of the first cooling surface 112 corresponding to the planned arrangements of the battery cells 102 (i.e., 112a, 112b, 112c, 112d, 112e, ... 112n).It is understood that the resolution of the cooling profile of the first cooling surface 112 can be any resolution.

[0023] Fig. Figure 3A shows a cross-sectional view through the center of an illustrative cooling plate 300 according to some embodiments of the present disclosure. A first region 302 may correspond to an inlet port of the cooling plate 300, while a second region 304 may correspond to an outlet port of the cooling plate 300. The first region 302 and the second region 304 may be connected by a channel 306. Coolant may enter the cooling plate 300 at the inlet port through region 302 and flow along channel 306 before reaching the second region 304 and exiting the cooling plate 300 through the outlet port (i.e., in the direction indicated by the arrows). As the coolant flows through the cooling plate 300, it absorbs heat and becomes warmer.Accordingly, even if the arrangement of the channel 306 is optimized for a planned arrangement of the battery cells 102, the cooling profile of the cooling plate 300 can still vary across its cooling surface. For example, as shown, the coolant flows through the channel 306 in one direction from the first planned battery cell placement 112a to the fifth planned battery cell placement 112e. Thus, more cooling power can be provided to the battery cell 102 at the first planned battery cell placement 112a than, for example, to the battery cell 102 at the fifth planned battery cell placement 112e. However, as explained above, the cooling profile of the first cooling surface 112 can vary due to other factors (e.g., distance to an edge, proximity to other batteries, electrical components, etc.).

[0024] Returning to Fig. 1. The first end 104 of the battery cells 102 can be attached to the first cooling surface 112 by the adhesive 108. The electrical, thermal, and mechanical properties of the adhesive 108 of this disclosure can meet the design and manufacturing requirements associated with the battery module 100. In some embodiments of this disclosure, the adhesive 108 can be a thermal interface material whose thermal conductivity can be varied. In some embodiments of this disclosure, the adhesive 108 can include at least two different components with different thermal conductivities. For example, the adhesive 108 can include at least two different resins (e.g., an epoxy resin, a polyester resin, an acrylic resin, etc.) and a curing agent (e.g., a hardener or an initiator).By varying the ratio of the two resin components in the adhesive 108, the thermal conductivity of the adhesive 108 can be varied. Of course, this is only one example, and the adhesive can have more than two different resin components with different thermal conductivities. In some embodiments, the adhesive 108 can include a resin and at least two different curing agents with different thermal conductivities.

[0025] In some embodiments of the present disclosure, the first component of the adhesive (a first resin) can have a higher thermal conductivity than the second component of the adhesive (a second resin). For example, the first resin can have a thermal conductivity of 1.4 W / m*K. However, this is only an example, and the first resin can have a thermal conductivity of more than or equal to 1.0 W / m*K. The second resin can have a thermal conductivity of 0.1 W / m*K. However, this is only an example, and the second resin can have a thermal conductivity of less than or equal to 0.3 W / m*K.

[0026] In some embodiments of the present disclosure, the ratio of the first resin to the second resin in the adhesive 108 can be varied based on the cooling profile of the first cooling surface 112. By varying the ratio between the first and second resins in the adhesive 108 based on the cooling profile of the first cooling surface 112, the adhesive 108 can compensate for variations in the cooling performance across the first cooling surface 112 and provide uniform cooling for each of the battery cells 102 mounted thereon. For example, the first resin has a thermal conductivity of 1.0 W / m*K and the second resin has a thermal conductivity of 0.3 W / m*K. The thermal conductivity of the adhesive 108 can be varied from 0.3 W / m*K to 1.0 W / m*K by varying the ratio of the first resin to the second resin from 0 / 100 to 100 / 0.

[0027] In some embodiments of the present disclosure, the thermal conductivities of the first and second resins can be varied by doping with standard additives that are thermally conductive but electrically insulating, such as aluminum oxide, boron nitride, aluminum oxide trihydrate, or magnesium hydroxide. The latter two materials can impart additional flame-retardant properties to the mixed adhesive, albeit at the cost of lower thermal conductivity relative to weight. In some embodiments of the present disclosure, the viscoelastic properties of the second resin can be modified to match those of the first resin by adding additives with low thermal conductivities, such as pyrogenic silica or other thickening agents, to increase viscosity while keeping thermal conductivity low.In some embodiments of the present disclosure, it may be advantageous for the thermal conductivities of both the first and the second resin to be high in order to maximize the cooling provided by the first cooling surface 112. For example, if the cooling profile of the first cooling surface 112 does not involve a large variation across the first cooling surface 112, the difference between the thermal conductivities of the first and second resins may be smaller than the entire range of possible thermal conductivities.

[0028] In some embodiments of the present disclosure, in order to maximize the cooling provided by the first cooling surface 112, the adhesive 108 with the highest possible thermal conductivity should be applied to the area of ​​the first cooling surface 112 with the lowest conductivity for cooling performance (e.g., a ratio of 100 / 0 of the first resin to the second resin). In some embodiments of the present disclosure, the ratio of the first resin to the second resin may be limited to a minimum amount of either the first resin or the second resin (e.g., 10 / 90), for example, due to limitations on the ratio of the resins or the manner in which they are applied.

[0029] In some embodiments of the present disclosure, it may be advantageous to maintain the uniformity of the thickness of the cured adhesive 108 so that the battery cells 102 are spaced equally from the first cooling surface 112. In some embodiments of the present disclosure, the thickness of the adhesive 108 can be controlled by impregnating the adhesive with glass beads (or other materials) of a predetermined size. In some embodiments of the present disclosure, the thickness of the adhesive 108 can be controlled by using pre-cured adhesive spacers to maintain the uniform distance between each of the battery cells 102 and the first cooling surface 112 while the adhesive 108 cures.In addition to securing the battery cells 102 to the first cooling surface 112 and compensating for fluctuations in cooling performance via the first cooling surface 112, the adhesive 108 should also maintain electrical insulation between the battery cells 102 and the first cooling surface 112, as well as electrical insulation between each parallel-connected group of battery cells 102. Therefore, the adhesive 108 should also possess sufficient dielectric properties.

[0030] Fig. Figure 3B shows the adhesive 108 with different thermal conductivities, which is applied to the first cooling surface 112 of the illustrative cooling plate 300, according to some embodiments of the present disclosure. To avoid making the description too complicated, Figure 3B shows the adhesive 108 with different thermal conductivities, which is applied to the first cooling surface 112 of the illustrative cooling plate 300, according to some embodiments of the present disclosure. Fig. 3B, that the adhesive 108 is applied only to the first planned battery cell placement 112a up to the fifth planned battery cell placement 112e. However, it is understood that the adhesive 108 is applied to all planned battery cell placements or the entire area within the battery assembly area 202. As shown by various filling patterns,The ratio of the first resin to the second resin of the adhesive 108 can be varied for each of the first planned battery cell placements 112a to the fifth planned battery cell placement 112e based on the cooling profile of the first cooling surface 112. In some embodiments of the present disclosure, the cooling profile of the first cooling surface 112 can include an average cooling performance for each of the first planned battery cell placements 112a to the fifth planned battery cell placement 112e. In this case, a different ratio of the first resin to the second resin of the adhesive 108 can be determined for each of the planned battery cell placements. For example, if the cooling profile of the first cooling surface 112 indicates that the cooling performance of the first cooling surface 112 decreases slowly from the first planned battery cell placement 112a to the fifth planned battery cell placement 112e,The ratio of the first resin (with high thermal conductivity) to the second resin (with low thermal conductivity) can increase slowly, so that each of the battery cells 102, provided at the first planned battery cell placement 112a up to the fifth planned battery cell placement 112e, is cooled uniformly. Although, as shown, the first planned battery cell placement 112a has a first ratio 108a of the first resin to the second resin of the adhesive 108, the second planned battery cell placement 112b has a second ratio 108b of the first resin to the second resin of the adhesive 108, the third planned battery cell placement 112c has a third ratio 108c of the first resin to the second resin of the adhesive 108, and the fourth planned battery cell placement 112d has a fourth ratio 108d of the first resin to the second resin of the adhesive 108,and the fifth planned battery cell placement 112e has a fifth ratio 108e of the first resin to the second resin of the adhesive 108, this is only an example, and the ratio of the first resin to the second resin of the adhesive 108 can gradually change across each of the planned battery cell placements or the entire area within the battery assembly area 202. After the adhesive 108 has been applied to the first cooling surface 112, the battery cells 102 can be arranged on the adhesive 108.

[0031] Fig. Figure 4 shows a view of a battery module 400 according to some embodiments of the present disclosure. As shown, the battery module 400 corresponds to the battery module 100, except that a plurality of battery cells 122 are provided on the second cooling surface 114. The battery cells 122 can be provided in the same manner as described above with reference to the battery cells 102 and the first cooling surface 112.

[0032] Fig. Figure 5 shows a block diagram of a device 500 for mixing and applying the adhesive 108 to the first cooling surface 112 of the cooling plate 110 according to some embodiments of the present disclosure. However, this is only one example, and the device 500 can alternatively (or additionally) apply the adhesive 108 to the first end 104 of each of the battery cells 102. Although the device 500 can apply the adhesive 108 to the second cooling surface 114 of the cooling plate 110 (and / or the end of each of the battery cells 122), only the first cooling surface 112 is discussed here to avoid overly complex descriptions. As shown, the device 500 can include a controller 501 and an adhesive dispersion module 503 connected to the controller. Although the controller 501 and the adhesive dispersion module 503 are shown as separate devices (e.g.,(wired or wirelessly connected), the control unit 501 and the adhesive dispersion module 503 can be enclosed in the same device.

[0033] The controller 501 can include a control circuit 502, which includes a memory 504 and a processing circuit 506, as well as an input / output path (I / O path) 508. The controller 501 can receive content and data via the I / O path 508. For example, cooling profiles and planned arrangements of battery cells can be received via the I / O path 508.

[0034] The control circuit 502 can be based on any suitable processing circuit, such as the processing circuit 506. As mentioned herein, a processing circuit is understood to be a circuit based on one or more microprocessors, microcontrollers, digital signal processors, programmable logic devices, field-programmable gate arrays, application-specific integrated circuits, etc. In some embodiments of the present disclosure, the control circuit 502 executes instructions stored in a memory (i.e., the memory 504) to control various sections of the device 500 and to perform the functions discussed above and below. For example, the control circuit 502 executes instructions to control the adhesive dispersing module 503.

[0035] The adhesive dispersion module 503 applies the adhesive 108 to the first cooling surface 112 of the cooling plate 110. As shown, the adhesive dispersion module 503 can include a first resin 510, a second resin 512, and a hardener 514. Based on the cooling profile of the first cooling surface 112, the control circuit 502 can control the mixing module 516 to mix varying ratios of the first resin 510 and the second resin 512 with the hardener 514 to compensate for the variable cooling performance of the cooling surface. The control circuit 502 can control the adjustment motor 522 to change the position of the nozzle 518 for applying the mixed adhesive 108 to the first cooling surface 112. Although only a single nozzle 518 is shown, this is just an example, and the nozzle 518 can contain multiple nozzles.For example, the mixing module 516 can include several mixing modules for separately mixing the first resin 510 with the hardener 514 and the second resin 512 with the hardener 514. The separately mixed resins 510 and 512 can then be applied to the first cooling surface 112 through separate nozzles. In some embodiments of the present disclosure, the first resin 510, the second resin 512, and the hardener 514 can be mixed in the nozzle 518. In some embodiments of the present disclosure, the nozzle 518 can include a three-way mixing head, three separate mixing heads, or two mixing heads to distribute the first resin 510, the second resin 512, and the hardener 514 onto the first cooling surface 112.

[0036] The adjustment motor 522 can contain any number of motors (e.g., servo motors, stepper motors, etc.) for adjusting the position of the nozzle 518 relative to the first cooling surface 112. The adjustment motor 522 can be controlled by the control circuit 502.

[0037] The adhesive dispersion module 503 can additionally include sensors 520 (e.g., a camera or other suitable sensor) to monitor the distribution of the adhesive 108 on the first cooling surface 112 or to meter the quantities of the first resin 510, the second resin 512, and the hardener 514 supplied to the mixing module 516. The output of the sensors 520 can be provided to the controller 501, which can use the output to control the operation of the adhesive dispersion module 503.

[0038] Fig.Figure 6 shows a flowchart of an illustrative method 600 for manufacturing a battery module 100 according to some embodiments of the present disclosure. To avoid an overly complicated description, the method 600 is described with respect to only two battery cells 102 in the battery module 100. However, it is understood that the method 600 can be used to manufacture the battery module 100 (or the battery module 400) with any suitable number of battery cells 102.

[0039] In step 602, a cooling surface is provided. The cooling surface can be the first cooling surface 112 of the cooling plate 110, as described above.

[0040] In step 604, a cooling profile of the cooling surface can be determined. As described in detail above, the cooling profile can be determined by experimentation (e.g., by measuring the cooling power across the cooling surface) or by modeling the cooling profile of the cooling surface. In some embodiments of the present disclosure, the cooling profile can be retrieved from a database (e.g., by the controller 501 via the I / O path 508).

[0041] In step 606, ratios of a first resin with a first thermal coefficient to a second resin with a second thermal coefficient of an adhesive (e.g., adhesive 108) can be determined to compensate for differences in cooling performance in the first and second areas of the cooling surface based on the cooling profile (e.g., where the multitude of battery cells is arranged). For example, the control circuit 502 can determine the ratios based on the cooling profile of the cooling surface.

[0042] In step 608, the adhesive can be supplied to the first and second regions of the cooling surface in specific ratios to compensate for differences in cooling performance between these regions. For example, the controller 501 can control the adhesive dispersing module 503 to supply the adhesive to the first and second regions in these specific ratios. As described above, the ratio (of the first resin to the second resin) of the adhesive supplied to a region (e.g., the first or the second region) can be a uniform ratio across the entire region or a ratio that varies across the region.

[0043] In step 610, a first battery cell and a second battery cell can be provided.

[0044] In step 612, the first ends of the first and second battery cells can be attached to the cooling surface using the adhesive. For example, the first end of the first battery cell can be attached to the first area using the adhesive with a first ratio of the first resin to the second resin, and the first end of the second battery cell can be attached to the second area using the adhesive with a second ratio of the first resin to the second resin that differs from the first ratio. To secure the first and second battery cells to the cooling surface, their first ends can be pressed into the adhesive before it cures.

[0045] It is understood that, although Method 600 has been described in connection with the manufacture of a battery module and the attachment of battery cells to a cooling surface, Method 600 can be used to attach any two components to a surface using an adhesive if a different thermal conductivity of the adhesive is desired.

[0046] The foregoing serves only to illustrate the principles of this disclosure, and various modifications may be made by a person skilled in the art without deviating from the scope of protection of this disclosure. The embodiments described above are presented for illustrative purposes and are not intended to be limiting. This disclosure may also take many other forms than those expressly described herein. Accordingly, it is emphasized that this disclosure is not limited to the explicitly disclosed methods, systems, and devices, but is intended to include variations and modifications thereof that are within the spirit of the following claims.

Claims

[1] Battery module comprising: a cooling surface comprising a first area and a second area, wherein the first area and the second area have different cooling capacities; an adhesive comprising a first component with a first thermal conductivity and a second component with a second thermal conductivity; and a first battery and a second battery, where: a first end of the first battery is attached to the first area by a first section of the adhesive, and a first end of the second battery is attached to the second area by a second section of the adhesive, the first section of the adhesive has a first ratio of the first component to the second component, and the second section of the adhesive has a second ratio of the first component to the second component, and the first ratio and the second ratio are different and compensate for the different cooling capacities of the first area and the second area. [2] Battery module according to claim 1, wherein: Each of the first and second components is a resin, and the adhesive further comprises a hardener. [3] Battery module according to claim 1, further comprising a cooling plate, wherein the cooling surface forms a first side of the cooling plate. [4] Battery module according to claim 3, wherein the cooling plate further comprises an input port, an output port and a cooling channel, wherein a cooling fluid can flow through the cooling channel from the input port to the output port. [5] Battery module according to claim 1, wherein: the first area has a first cooling capacity and the second area has a second cooling capacity, where the first cooling capacity is greater than the second cooling capacity, the first thermal conductivity is greater than the second thermal conductivity, the first ratio of the first component to the second component is greater than the second ratio of the first component to the second component, and The first ratio and the second ratio compensate for the difference between the first cooling capacity and the second cooling capacity, so that the first battery and the second battery are provided with the same cooling capacity. [6] Battery module according to claim 1, wherein: the first thermal conductivity is greater than or equal to 1.0 watt / meter*kelvin (W / m*K), and the second thermal conductivity is less than or equal to 0.3 W / m*K. [7] Battery module according to claim 1, wherein the adhesive further comprises a plurality of ridges to space the first end of each of the first battery and the second battery at a predetermined distance from the cooling surface. [8] Battery module according to claim 1, wherein the cooling surface is a first cooling surface, and wherein the battery module further comprises: a second cooling surface opposite the first cooling surface, wherein the second cooling surface comprises a third area and a fourth area, the third and fourth areas have different cooling capacities; and a third battery and a fourth battery, where: a first end of the third battery is attached to the third area by a third section of the adhesive, and a first end of the fourth battery is attached to the fourth area by a fourth section of the adhesive, the third section has a third ratio of the first component to the second component, and the second section has a fourth ratio of the first component to the second component, and the third ratio and the fourth ratio are different and compensate for the different cooling capacities of the third area and the fourth area, so that a similar cooling capacity is provided to the third battery and the fourth battery. [9] Battery module according to claim 1, wherein: The first ratio is an average ratio of the first component to the second component of the first section, and The ratio of the first component to the second component of the first section within the first area varies. [10] Battery module according to claim 1, wherein the first ratio is consistent within the first section. [11] Method for assembling a battery module, comprising: Providing a cooling surface, wherein a cooling performance of the cooling surface varies across the cooling surface; Providing an adhesive comprising a first component having a first thermal conductivity to a second component having a second thermal conductivity; Provide a first battery and a second battery; Applying the adhesive to a first area of ​​the cooling surface with a first ratio of the first component to the second component; Applying the adhesive to a second area of ​​the cooling surface with a second ratio of the first component to the second component; Attaching one end of the first battery to the first area using the adhesive applied to the first area; and attaching one end of the second battery to the second area using the adhesive applied to the second area. where the first ratio and the second ratio are different and compensate for the different cooling capacities of the first area and the second area. [12] Method according to claim 11, wherein: Each of the first and second components is a resin, and the adhesive further comprises a hardener. [13] Method according to claim 11, further comprising providing a cooling plate comprising an inlet port, an outlet port and a cooling channel, wherein the cooling surface forms a first side of the cooling plate. [14] Method according to claim 11, further comprising determining a cooling profile of the cooling surface, wherein the cooling profile comprises the cooling power provided at each point via the cooling surface. [15] The method of claim 14, further comprising: Determining an initial cooling capacity to be provided at the first area on the cooling surface, based on the cooling profile; and Determining a second cooling capacity to be provided at the second area on the cooling surface, based on the cooling profile, where the first ratio and the second ratio compensate for the difference between the first cooling capacity and the second cooling capacity, so that the first battery and the second battery are provided with the same cooling capacity. [16] Method according to claim 11, wherein: the first thermal conductivity is greater than or equal to 1.0 watt / meter*kelvin (W / m*K), and the second thermal conductivity is less than or equal to 0.3 W / m*K. [17] Method according to claim 11, further comprising providing a plurality of ridges in the adhesive to space the first end of each of the first battery and the second battery at a predetermined distance from the cooling surface. [18] The method of claim 11, wherein the cooling surface is a first cooling surface and wherein the method further comprises: Providing a second cooling surface opposite the first cooling surface, wherein the cooling performance of the second cooling surface varies across the second cooling surface; Providing a third battery and a fourth battery; Applying the adhesive with a third ratio of the first component to the second component to a third area of ​​the second cooling surface; Applying the adhesive with a fourth ratio of the first component to the second component to a fourth area of ​​the second cooling surface; Attaching one end of the third battery to the third area using the adhesive applied to the third area; and Attaching one end of the fourth battery to the fourth area using the adhesive applied to the fourth area, where the third ratio and the fourth ratio are different and compensate for the different cooling capacities of the third area and the fourth area. [19] Method according to claim 11, wherein: The first ratio is an average ratio of the first component to the second component of the adhesive applied to the first area, and The ratio of the first component to the second component of the adhesive applied to the first area varies within the first area. [20] Method according to claim 11, wherein the first ratio is consistent within the first region.

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