Battery Pack Filler Application Pattern for Thermal Conduction
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Solution Overview
Problem
Existing methods of applying a thermally conductive filler between a battery module and a housing body result in uncovered regions due to filler spread, leading to potential air entrapment and reduced performance.
Innovation Solution
A method involving the application of a filler with a pattern of alternating folded portions and displaced ends to minimize uncovered areas, ensuring less than 30% of the filler area is uncovered.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the filler is applied simply between the battery module and housing body, then the application process is simple, but air becomes surrounded by the filler spread during compression, creating uncovered regions
Solution Approach 1:
The filler application is segmented into multiple sequential applications rather than a single application. Each application covers specific areas, and subsequent applications fill gaps and uncovered regions, ensuring complete coverage without surrounding air pockets
Solution Approach 2:
The filler is applied in advance in a controlled pattern before the compression step. By pre-positioning the filler in specific configurations, the subsequent compression spreads the filler uniformly without trapping air, eliminating the need for complex real-time adjustment during assembly
2Ease of manufacture
If the filler is applied in a simple pattern, then the application process is easy, but uncovered regions remain after compression
Solution Approach 1:
Different regions of the filler application have different patterns optimized for their specific locations. The filler is applied with varying densities and configurations in different areas to ensure complete coverage and optimal thermal conduction in each local region, preventing uncovered areas that would compromise reliability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Reduces uncovered regions, enhancing thermal conduction and joint integrity between battery module and housing, thereby improving battery pack performance.
Implementation Method 1
a thermally conductive member is provided between the battery module and the housing body
Implementation Method 2
a method of joining battery cells with each other with an adhesive
Data Source
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AI summary
A method of manufacturing a battery pack (10) includes a step of applying an applied filler (150A) onto at least a portion of a housing body (200), and a step of mounting a battery module (100) on the at least a portion of the housing body (200) via the applied filler (150A). In the step of applying the applied filler (150A), the applied filler (150A) has a pattern including a plurality of folded portions arranged alternately.