Battery Module Hot-Melt Stacking for Alignment and Heat Dissipation
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Solution Overview
Problem
Existing battery modules face challenges in maintaining a stable stacked structure and efficient heat dissipation due to misalignment and inadequate adhesive strength, particularly under severe driving conditions like high temperature and vibration, which affects the performance and lifespan of electric vehicle batteries.
Innovation Solution
A battery module design featuring stacked battery cells with hot melt coating between them to secure alignment, paired with end plates and bus bar assemblies for electrical connection, and a gap filler for heat dissipation, allowing for a standardized and robust configuration suitable for various vehicle types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If battery cells are stacked without hot melt coating, then manufacturing is simpler, but the stacked structure becomes unstable and misalignment occurs
Solution Approach 1:
Hot melt coating is introduced as an intermediary substance between battery cells to achieve stable stacking. The hot melt serves as a bonding agent that fills gaps and secures alignment between cells, preventing misalignment while maintaining manufacturing feasibility through a straightforward coating process.
2Strength
If conventional adhesive methods are used, then manufacturing is easier, but adhesive strength is insufficient under high temperature and vibration
Solution Approach 1:
The adhesive properties are enhanced by changing parameters of the hot melt material, including its melting point, viscosity, and bonding characteristics. These parameter adjustments enable the hot melt to maintain strong adhesive strength under severe conditions such as high temperature and vibration, while the application process remains relatively simple.
3Loss of energy
If battery cells are tightly stacked without gap filler, then structure is more compact, but heat dissipation becomes inefficient
Solution Approach 1:
Gap filler is selectively applied in specific locations between battery cells where heat accumulation occurs. This localized approach improves heat dissipation efficiency by creating thermal pathways without significantly increasing the overall module volume. The gap filler is positioned strategically to optimize heat transfer while maintaining compact dimensions.
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 stabilizes the battery module structure, enhances adhesive strength, simplifies manufacturing, and improves heat dissipation, leading to improved performance and extended lifespan of electric vehicle batteries across different environments.
Implementation Method 1
hot melt being coated and fixing between at least some of the plurality of battery cells
Implementation Method 2
a gap filler for heat dissipation
Data Source
AI summary
A battery module includes a plurality of battery cells stacked on one another in a first direction, hot melt being coated and fixing between at least some battery cells of the plurality of battery cells, and a pair of end plates that surface-contact with opposite end battery cells of a stacked structure in which the plurality of battery cells is stacked and fix a distance therebetween.