Battery Module Resin Flow Control for Lighter Thermal Management
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Solution Overview
Problem
Existing battery modules face issues with excessive injection and permeation of thermally conductive resin, leading to increased costs and weight, which is not effectively managed by current designs.
Innovation Solution
Incorporation of a blocking film and adhesive layers, such as double-sided tapes, to prevent thermally conductive resin from permeating between battery cells and compression pads, combined with a thermally conductive resin layer to manage heat transfer and module fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If thermally conductive resin is injected through liquid injection holes to transfer heat and fix battery cells, then heat transfer capability and structural stability are improved, but excessive resin permeation occurs between battery cells and compression pads, leading to increased weight and additional cost
Solution Approach 1:
The patent divides the resin injection process into controlled segments by forming separate injection holes at specific locations (front surface and side surface of module frame) rather than allowing unrestricted resin flow. This segmentation prevents excessive resin permeation between battery cells while ensuring adequate heat transfer at critical interfaces.
Solution Approach 2:
The patent applies thermally conductive resin locally at specific interfaces where heat transfer is most needed (between battery cells and module frame, and at compression pad interfaces) rather than uniformly throughout the entire module. This localized application reduces overall resin quantity and weight while maintaining effective heat transfer pathways.
2Temperature
If thermally conductive resin is injected to ensure adequate filling between module frame and battery cell stack, then thermal management effectiveness is improved, but resin permeates into spaces where it is not needed, increasing material cost and weight
Solution Approach 1:
The patent performs preliminary positioning of battery cells and compression pads before resin injection, and pre-forms injection holes at optimal locations. This preliminary arrangement ensures that resin flows only to necessary areas during injection, preventing waste and reducing the total quantity of resin required while maintaining effective thermal management.
Solution Approach 2:
The patent uses compression pads as intermediary elements between battery cells and module frame, which are positioned and secured before resin injection. These intermediaries create defined pathways that guide resin flow to where it is needed for thermal management, preventing unnecessary resin permeation into other spaces.
3Ease of manufacture
If liquid injection holes are formed on the bottom part of module frame for resin injection, then manufacturing process is simplified, but resin permeates excessively along arrow direction creating dummy resin layers
Solution Approach 1:
The patent transitions from a single injection approach (bottom surface only) to a multi-dimensional injection strategy by forming holes on both the front surface and side surface of the module frame. This multi-directional approach allows precise control of resin flow paths, preventing excessive permeation and dummy layer formation while maintaining manufacturing simplicity.
Solution Approach 2:
The patent creates locally optimized injection holes at specific positions on the front and side surfaces where resin flow is most effective. This localized hole placement ensures resin is delivered precisely where needed for thermal management, preventing waste and improving manufacturing precision without complicating the overall process.
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
Prevents additional resin injection, reduces module weight, and minimizes cost by controlling resin distribution, enhancing the efficiency and economy of battery modules.
Implementation Method 1
A thermally conductive resin may be injected between the battery cell stack 15 and the module frame 10 through the liquid injection holes 20, and may form a thermally conductive resin layer 40... The thermally conductive resin layer 40 may serve to transfer heat generated from the battery cell stack 15 to the outside of the battery module
Implementation Method 2
Incorporation of a blocking film and adhesive layers, such as double-sided tapes, to prevent thermally conductive resin from permeating between battery cells and compression pads
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A battery module according to an embodiment of the present disclosure may include: a battery cell stack, in which a plurality of battery cells are stacked; a module frame accommodating the battery cell stack; a thermally conductive resin layer located between a lower surface of the module frame and the battery cell stack; and a first adhesive layer located between adjacent battery cells, among the plurality of battery cells, and a liquid injection hole for injecting a thermally conductive resin may be formed on the lower surface of the module frame and the first adhesive layer is formed adjacent to the thermally conductive resin layer.