Battery Module Filler Layout to Reduce Glue Overflow and Weight
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Solution Overview
Problem
Existing glue filling methods for battery modules result in glue overflow, residual glue, and poor heat dissipation, leading to lower energy density and increased costs.
Innovation Solution
A method involving upside-down filling of a filler into an accommodating cavity of a fastening frame, which fastens the battery cell assembly and adapting plate, using fewer fillers to improve energy density and protect against shock and vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple batteries are bundled together to form a battery module, then the battery module can be used in applications requiring higher capacity, but the inconsistency in usage time among batteries becomes more significant
Solution Approach 1:
A current balancing device is introduced as an intermediary component between batteries with different capacities. This device actively monitors and adjusts current distribution to ensure that batteries discharge at balanced rates, preventing the capacity-rich battery from being underutilized and the capacity-poor battery from being overcharged or depleted prematurely.
Solution Approach 2:
The system dynamically changes operational parameters (current distribution, discharge rates) based on real-time battery state monitoring. By adjusting these parameters, the system optimizes the usage of batteries with varying capacities, ensuring consistent overall performance and extending the effective usage time of the battery module.
2Duration of action of moving object
If a current balancing device is added to manage batteries with different capacities, then usage time consistency is improved, but the device complexity increases
Solution Approach 1:
The current balancing device incorporates automatic monitoring and control mechanisms that operate autonomously based on real-time battery state feedback. The system self-adjusts current distribution without requiring external intervention or complex manual control systems, reducing operational complexity while maintaining usage time consistency.
3Reliability
If a current balancing device is used to prevent overcharging of capacity-poor batteries, then reliability is improved, but the loss of energy increases due to active current management
Solution Approach 1:
The current balancing device employs real-time feedback mechanisms that continuously monitor battery states and adjust current distribution accordingly. This feedback control prevents energy waste by directing current only when and where it is needed, minimizing unnecessary energy losses while maintaining reliable operation and preventing overcharging of capacity-poor batteries.
Data Source
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AI summary
This application discloses a method for manufacturing a battery module, including: disposing an adapting plate on a battery cell assembly, and connecting the adapting plate to tabs of the battery cell assembly; providing a fastening frame, where the fastening frame is provided with an accommodating cavity, and the accommodating cavity accommodates the adapting plate and at least part of the battery cell assembly; and providing a filler in a gap between the inner side of the accommodating cavity and the battery cell assembly and a gap between the inner side of the accommodating cavity and the adapting plate. This application further discloses a battery module, and a battery pack and an unmanned aerial vehicle that include the battery module.