Battery Module Resin Injection Holes for Uniform Adhesive Distribution
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Solution Overview
Problem
Existing battery modules face challenges in uniformly distributing adhesive resin to long cells, leading to poor fixability and heat dissipation, and lack a method to easily check resin distribution and remove internal air during injection.
Innovation Solution
A battery module design with resin injection holes distributed in two columns on either side of the center, allowing for even resin distribution, and including resin checking holes for visual confirmation and air discharge, ensuring proper resin filling and preventing bubble formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If adhesive resin is injected through conventional center injection holes in long battery cells, then the injection process is simple, but the resin distribution becomes non-uniform and fails to reach edge regions
Solution Approach 1:
The single center injection hole is segmented into multiple injection holes distributed across the module case. Specifically, first injection holes are arranged in a first column and second injection holes are arranged in a second column, allowing resin to be injected from multiple locations simultaneously to achieve uniform distribution across long battery cells.
Solution Approach 2:
The injection hole arrangement transitions from a single-point (center) injection to a multi-point distributed injection pattern. The injection holes are positioned at different locations including edge regions, transforming the injection geometry from one-dimensional center-based to two-dimensional distributed pattern for improved resin flow coverage.
2Reliability
If the module case is sealed tightly to protect battery cells, then structural stability is improved, but air trapped during resin injection cannot be discharged causing bubbles
Solution Approach 1:
Air discharge holes are introduced as intermediary features in the module case to facilitate air escape during resin injection. These holes provide a dedicated pathway for trapped air to be discharged externally, preventing bubble formation in the adhesive resin while maintaining the overall sealed structure for structural stability.
Solution Approach 2:
Air is extracted from the enclosed space between the battery cell stack and module case through dedicated air discharge holes. This extraction function is separated from the sealing function, allowing the module case to maintain both tight sealing for structural integrity and air discharge capability during the injection process.
3Measurement precision
If CT scan is used to check internal resin distribution, then measurement accuracy is high, but the process becomes complex and time-consuming
Solution Approach 1:
The module case structure itself provides inspection functionality through transparent or translucent portions that allow direct visual observation of resin distribution. This self-inspection feature eliminates the need for complex external imaging equipment like CT scanners, enabling operators to verify resin filling status directly through the module case design.
Solution Approach 2:
The module case incorporates transparent or translucent materials that enable visual detection of resin distribution. The transparency acts as a visual indicator system, allowing the resin filling state to be observed directly without complex instrumentation, effectively using optical properties for quality verification.
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 enables improved fixability and heat dissipation by ensuring adhesive resin reaches all areas of long cells, reducing the need for CT scans and preventing bubble formation, resulting in a more compact and efficient battery module.
Implementation Method 1
injecting adhesive resin into the module case to fix the cell stack structure in the module case
Implementation Method 2
a conventional module case is not provided with a passage through which air can be externally extracted, bubbles may be generated in the adhesive resin
Data Source
AI summary
A battery module includes a cell stack structure formed as a plurality of battery cells stacked and accommodated in a module case. The module case includes at least one hole forming plate having a plurality of resin injection holes formed therein for receiving an adhesive resin therethrough, and the plurality of resin injection holes are distributed on both a left side and a right side of a center of the hole forming plate in a longitudinal direction thereof, such that the resin injection holes on the left side and the right side are spaced apart from each other by a predetermined distance from the center of the hole forming plate in the longitudinal dimension.