Battery Module Resin Injection for Immediate Quality Inspection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge in manufacturing battery packs is the flow-out of resin composition with low viscosity during the assembly process, which requires a waiting period of 3 to 4 hours for curing, hindering the end-of-line quality inspection and assembly efficiency.
Innovation Solution
A method involving the formation of a heat-dissipating adhesive layer on the lower plate of the battery module, where the resin composition is injected through an inlet, preventing flow-out and allowing immediate quality inspection without waiting for curing, utilizing a thermally conductive resin composition with a filler to ensure efficient heat dissipation and adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If resin composition with low viscosity is used for injection, then ease of injection is improved, but resin flow-out during assembly occurs
Solution Approach 1:
A support member is preliminarily installed at the injection inlet before resin injection. This support member acts as a physical barrier that prevents resin flow-out during subsequent assembly operations, while allowing the resin to be injected through the inlet without resistance. The preliminary installation of this protective structure resolves the contradiction by enabling low-viscosity resin use without causing flow-out issues.
2Reliability
If waiting time for resin curing is extended to prevent flow-out, then reliability is improved, but productivity deteriorates
Solution Approach 1:
The support member is designed to be easily removable after serving its protective function during assembly. Once the assembly is complete, the support member can be quickly taken out without requiring extended waiting time for resin curing. This allows the main assembly process to proceed at full speed while still preventing resin flow-out during critical operations, thus maintaining both reliability and productivity.
3Ease of manufacture
If resin composition with low viscosity is used, then ease of injection is improved, but heat dissipation capability deteriorates
Solution Approach 1:
The resin composition is formulated as a composite material that combines low-viscosity base resin with heat-dissipating fillers such as metal particles or ceramic particles. This composite structure allows the resin to maintain low viscosity for easy injection while the dispersed filler particles provide effective heat dissipation pathways. The support member also contributes to heat management by providing structural support during the heat dissipation 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
Enables efficient manufacturing by preventing resin flow-out and allowing immediate quality inspection, enhancing productivity and reducing assembly time while maintaining effective heat dissipation and adhesion properties.
Implementation Method 1
a heat-dissipating adhesive resin composition can be used as the resin composition
Implementation Method 2
a heat-dissipating adhesive resin composition can be used as the resin composition
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present application relates to a battery pack manufacturing method. The present application can provide a battery pack manufacturing method capable of performing quality inspection of a battery module before the resin composition injected into the battery module is sufficiently cured to fix battery cells contained in the battery module.