Battery Module Case Injection Hole Design for Thermal Adhesive Coating
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Solution Overview
Problem
Conventional battery modules face inefficiencies in thermally conductive adhesive injection, leading to potential damage of the battery cell assembly due to burrs, inaccurate nozzle insertion, and adhesive leakage during the cooling process.
Innovation Solution
A method for manufacturing a battery module involves strategically arranging the module case, forming convex and concave portions with rounded injection holes at the bottom, and injecting thermally conductive adhesive through these holes to ensure efficient coating and minimize damage, with options for horizontal or vertical orientation and varying spacing to enhance uniform distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If an injection hole is formed in the module case to inject thermally conductive adhesive, then thermal conductivity is improved, but the battery cell assembly may be damaged due to burr or inaccurate nozzle insertion
Solution Approach 1:
The injection hole is formed in advance in the module case before the battery cell assembly is installed. This preliminary action prevents the need to form holes after assembly, eliminating the risk of burr formation and inaccurate nozzle insertion that could damage the battery cells during later operations.
Solution Approach 2:
The manufacturing process is segmented into distinct stages: first forming the injection hole in the module case, then installing the battery cell assembly, and finally injecting the thermally conductive adhesive. This segmentation allows each operation to be optimized independently, preventing damage to the battery cells while ensuring proper adhesive injection.
2Temperature
If thermally conductive adhesive is injected into the module case, then cooling efficiency is improved, but adhesive may leak out of the module case
Solution Approach 1:
The injection hole is pre-formed in the module case with proper positioning and dimensions before adhesive injection. This preliminary preparation ensures that the adhesive is injected at the correct location and pressure, preventing leakage while achieving uniform distribution for effective cooling.
3Manufacturing precision
If multiple injection holes are provided in the bottom portion of the module case, then adhesive distribution uniformity is improved, but device complexity increases
Solution Approach 1:
The injection system is segmented into multiple injection holes distributed at specific positions in the bottom portion of the module case. This segmentation allows the thermally conductive adhesive to be injected at multiple locations simultaneously, ensuring uniform distribution across the battery cell assembly while maintaining a relatively simple module case structure.
Solution Approach 2:
Different regions of the bottom portion of the module case are equipped with injection holes at optimally spaced positions. This local quality approach ensures that each region receives adequate adhesive coverage, achieving uniform distribution without requiring excessive injection holes that would increase complexity.
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 method enhances the efficiency of thermally conductive adhesive injection, preventing damage to the battery cell assembly and ensuring effective cooling, while maintaining structural integrity and uniform adhesive distribution within the module case.
Implementation Method 1
a thermally conductive adhesive is applied to the inside of a module case to stably fix a battery cell assembly including at least one battery cell in the module case and to improve thermal conductivity
Data Source
AI summary
A method for manufacturing a battery module includes accommodating a battery cell assembly having at least one battery cell in a module case, and injecting a thermally conductive adhesive through at least one injection hole provided in a bottom portion of the module case so that the module case is coated with the thermally conductive adhesive.