Battery Gap Filler Injection Structure for Air-Free Cooling Contact
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In battery system assemblies for electric vehicles, the application of a gap filler to prevent overheating is hindered by issues such as non-optimal flatness and alignment of components, leading to inefficiencies in heat transfer, potential air layers, and increased weight and material costs, as well as the risk of the gap filler being pushed aside or torn due to cell position changes.
Innovation Solution
A battery gap filler injection structure that injects the gap filler between the cooling channel and the battery cell after the battery module is mounted, using a cooling channel with a penetrating portion and an injection nozzle to ensure precise filling and prevent air layers, optimizing the filler amount and maintaining contact between components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a gap filler is applied before a battery pack is seated in a lower case, then heat transfer efficiency is improved, but manufacturing precision deteriorates due to out-of-standard flatness and alignment between components
Solution Approach 1:
The gap filler is applied in advance to the cooling channel surface before the battery module is seated. This preliminary application ensures that when components are assembled with out-of-standard flatness and alignment, the gap filler is already in position to fill any resulting gaps, maintaining heat transfer efficiency without requiring high manufacturing precision
Solution Approach 2:
The invention changes the physical state and application parameters of the gap filler by applying it as a liquid or semi-liquid material that can flow and adapt to surface irregularities. This allows the gap filler to compensate for variations in flatness and alignment, effectively decoupling heat transfer performance from manufacturing precision requirements
2Temperature
If a gap filler is applied as much as 1 mm more than the appropriate amount, then heat transfer efficiency is maintained despite alignment issues, but weight and material cost increase
Solution Approach 1:
Instead of uniformly applying excessive gap filler throughout, the invention applies the gap filler locally and selectively to areas where gaps are likely to form due to alignment variations. This localized application maintains heat transfer efficiency at the critical interfaces while minimizing the total amount of gap filler material used, thereby reducing weight
3Temperature
If a gap filler is applied before battery module seating, then heat transfer is improved, but reliability deteriorates because the gap filler may be pushed aside or torn due to cell position changes
Solution Approach 1:
The gap filler is applied in advance to the cooling channel surface before battery module seating and cell position adjustments. By establishing the gap filler layer beforehand, it is already in position to accommodate subsequent cell movements and pressure applications without being pushed aside or torn, as it can deform and reposition itself during the assembly process
Solution Approach 2:
The invention utilizes the viscoelastic properties of the gap filler material, which allows it to transition from a softer state during assembly (accommodating cell position changes) to a more stable state after assembly (maintaining heat transfer). This parameter change in the material's physical state enables it to adapt to cell movements while maintaining reliability
4Temperature
If a gap filler is applied before battery module seating, then heat transfer is improved, but measurement precision deteriorates because inspection of air layer formation is not possible after seating
Solution Approach 1:
The gap filler is applied in advance to the cooling channel surface before battery module seating. This preliminary application allows for inspection and verification of proper gap filler coverage and thickness before the battery cells are installed. After seating, the gap filler is already in position to fill any air layers that may form, and the preliminary inspection ensures proper application without requiring post-assembly measurement
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
This approach enhances heat transfer efficiency, prevents air layer formation, and ensures the gap filler remains in place even with cell position changes, eliminating the need for separate inspections and reducing material usage and weight.
Implementation Method 1
a cooling channel is provided below the battery system, and the cooling channel is spatially separated from an area where the battery module is mounted to prevent an internal short circuit caused by a leakage of a refrigerant
Implementation Method 2
a cooling channel in which a coolant flows
Implementation Method 3
a gap filler is applied before a battery pack is seated in a lower case, which is a key process to prevent battery cells from overheating
Data Source
AI summary
An embodiment battery gap filler injection structure includes a cooling channel disposed below a battery cell and joined to a lower side of the battery cell, wherein the cooling channel is configured to allow a coolant to flow therethrough, and wherein the cooling channel includes an upper cooling channel plate disposed below the battery cell and a lower cooling channel plate disposed below the upper cooling channel plate and joined to the upper cooling channel plate to define a plurality of cooling passages, and a spacer disposed on the upper cooling channel plate, wherein the spacer is configured to contact the lower side of the battery cell to support the battery cell and to maintain a distance between the upper cooling channel plate and the lower side of the battery cell.