Battery Module Resin Damming Structure for Uniform Cooling
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Solution Overview
Problem
Existing battery modules face challenges in stably applying heat radiating resin for efficient cooling performance, leading to inconsistent cooling results and increased manufacturing costs due to uneven resin distribution.
Innovation Solution
A battery module design featuring an external expansion controlling pad with two main bodies and bridges that function as a dam to contain the heat radiating resin between the battery cell stacked body and the mono frame, ensuring uniform application and preventing overflow, along with internal expansion controlling pads to manage cell expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If heat radiating resin is injected into the case through an injection hole, then cooling performance can be improved, but the resin may not be stably applied in the designated area leading to uneven distribution and increased manufacturing costs
Solution Approach 1:
The patent applies expansion controlling pads to the battery cell stacked body before resin injection. These pads pre-establish controlled expansion spaces that guide the resin flow and ensure uniform distribution. By preparing the expansion control structure in advance, the resin is directed to fill designated areas evenly, preventing both under-filling and over-flowing, thus achieving stable application and improved manufacturing precision while maintaining cooling performance.
2Temperature
If heat radiating resin is injected into the case, then thermal conductivity can be improved, but the resin may be excessively applied leading to increased manufacturing costs
Solution Approach 1:
The expansion controlling pads are applied beforehand to define precise boundaries and volumes for resin placement. This preliminary structuring ensures that the resin is contained within the exact space needed for thermal management, preventing excessive application and material waste while maintaining adequate thermal conductivity.
Solution Approach 2:
The expansion controlling pads create localized zones with different properties - areas where resin should be present for thermal conduction and areas where it should be excluded. This local differentiation ensures resin is applied only where needed for cooling, optimizing thermal conductivity while minimizing material waste and cost.
3Temperature
If heat radiating resin is injected through an injection hole, then cooling performance can be enhanced, but the resin application process becomes complex and costly
Solution Approach 1:
The expansion controlling pads serve multiple functions: they manage cell expansion, define resin injection boundaries, and guide thermal conduction pathways. By combining these functions into a single component applied before injection, the patent simplifies the overall manufacturing process while maintaining enhanced cooling performance, reducing both process complexity and cost.
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 provides excellent liquid-injection quality and cooling performance by stabilizing the heat radiating resin application, reducing manufacturing costs and improving efficiency without additional processes.
Implementation Method 1
a heat radiating resin provided between the battery cell stacked body and the lower plate
Implementation Method 2
an external expansion controlling pad provided between the battery cell stacked body and the mono frame
Data Source
AI summary
A battery module including a battery cell stacked body in which a plurality of battery cells are adjacent each other in parallel and are stacked; a mono frame receiving the battery cell stacked body and including at least one opening opened in a length direction of the battery cell stacked body, and including an upper plate and a lower plate that are perpendicular to a stacked side of the battery cell stacked body and a pair of lateral plates in parallel to the stacked side of the battery cell stacked body; an external expansion controlling pad provided between the battery cell stacked body and the mono frame; and a heat radiating resin provided between the battery cell stacked body and the lower plate. The external expansion controlling pad includes two main bodies and two bridges connecting the two main bodies.