Battery Module Frame with Injection and Insertion Holes
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Solution Overview
Problem
Conventional battery modules face challenges in maintaining a consistent space for thermally conductive resin injection, leading to unnecessary weight increase and increased manufacturing costs due to resin overflow caused by component movement under gravity.
Innovation Solution
A battery module design featuring a frame member with an injection hole in the lower surface and an insertion hole in the upper surface for a supporting jig, which maintains a constant resin injection space by preventing component movement during resin injection, and includes a thermally conductive resin layer and insulating cover to manage heat transfer and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the battery module is turned over 180 degrees to inject thermally conductive resin, then the resin can be injected through the injection hole in the bottom portion, but the battery cell stack moves downward by gravity causing the injection space to widen and resin to overflow
Solution Approach 1:
The patent applies preliminary action by forming a protrusion on the bottom portion of the frame member before resin injection. This protrusion pre-establishes a physical barrier that limits the downward movement of the battery cell stack during resin injection, thereby maintaining consistent injection space and preventing resin overflow before the actual injection process begins.
Solution Approach 2:
The protrusion acts as an intermediary element between the frame member and the battery cell stack. It mediates the interaction by providing a mechanical stop that prevents direct contact and movement between these components during resin injection, thereby maintaining space consistency without requiring complex fixation mechanisms.
2Ease of manufacture
If the battery module is turned over 180 degrees for resin injection, then injection can proceed through the bottom injection hole, but components inside the battery module move downward by gravity
Solution Approach 1:
The protrusion is pre-formed on the frame member to establish a mechanical constraint before injection. This preliminary structural feature ensures that when the module is turned over for injection, the battery cell stack is already prevented from moving downward, maintaining position stability throughout the injection process.
Solution Approach 2:
The protrusion creates a new equilibrium position for the battery cell stack during the inverted injection process. By providing a mechanical stop at a specific height, it establishes a stable position that counteracts the gravitational force, allowing the system to maintain component stability even when inverted for injection.
3Quantity of substance
If more thermally conductive resin is injected to ensure complete filling, then the injection space can be fully utilized, but resin overflows through the checking hole causing weight increase and cost increase
Solution Approach 1:
The protrusion pre-defines the maximum injection depth by creating a physical barrier. This preliminary structural constraint ensures that resin injection stops automatically when the protrusion is reached, preventing overflow through the checking hole and eliminating the need for excessive resin injection while ensuring complete filling of the intended space.
Solution Approach 2:
The protrusion provides visual and physical feedback during the resin injection process. As resin fills the space, the operator can observe the resin level approaching the protrusion, providing feedback that signals when to stop injection. This prevents over-injection and resin overflow while ensuring complete filling of the designated space.
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
The solution effectively prevents resin overflow, reduces manufacturing costs, and maintains a consistent resin injection space, thereby minimizing weight increase and ensuring efficient heat transfer in battery modules.
Implementation Method 1
The thermally conductive resin layer may serve to transfer heat generated from the battery cell stack to the outside of the battery module
Data Source
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AI summary
A battery module according to one embodiment of the present disclosure comprises: a battery cell stack in which a plurality of battery cells are stacked, and a frame member accommodating the battery cell stack and having an upper surface and a lower surface corresponding to each other, wherein an injection hole for injecting a thermally conductive resin is formed in the lower surface of the frame member, and wherein an insertion hole through which a protrusion of a supporting jig passes is formed in the upper surface of the frame member.