Battery Module Resin Layer Layout for Compact Cell Stack Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery modules face challenges in efficiently utilizing interior space and applying a precise amount of thermally conductive resin, leading to unnecessary consumption and wasted space.
Innovation Solution
A battery module design with a module frame that includes distinct areas for thermally conductive resin layers, allowing for precise application and distribution, and a method of vertically assembling the cell stack to optimize space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the mono frame height is designed high to accommodate cell stack tolerance, then the cell stack can be assembled, but unnecessary wasted space is created
Solution Approach 1:
The patent applies preliminary action by pre-forming recesses in the mono frame bottom part before cell stack assembly. These recesses are designed to accommodate the cell stack height and tolerance variations, allowing the cell stack to be assembled without requiring excessive frame height. The recesses are created in advance to match the expected cell stack dimensions, thereby eliminating wasted space while ensuring proper assembly accommodation.
2Strength
If thermally conductive resin is injected through injection hole to fix cell stack, then the cell stack is secured, but precise amount control of resin is difficult leading to unnecessary consumption
Solution Approach 1:
The patent extracts the injection hole from the mono frame structure, eliminating the need for resin injection through the frame. Instead, thermally conductive resin is applied directly to the bottom surface of the cell stack or to the recesses in the mono frame bottom part. This direct application method allows precise control of the resin amount, ensuring that only the necessary quantity is used for fixation and thermal conduction, thereby reducing unnecessary consumption.
Solution Approach 2:
The patent introduces the bottom part of the mono frame with pre-formed recesses as an intermediary between the cell stack and the frame body. These recesses serve as controlled receptacles for the thermally conductive resin, allowing precise placement and amount control. The resin is contained within the recesses, which act as intermediaries to distribute and limit the resin quantity, ensuring precise application while maintaining strong fixation and thermal conduction.
3Ease of manufacture
If clearance is created due to press-fitting, then components can be assembled, but unnecessary space is wasted
Solution Approach 1:
The patent applies local quality by creating recesses only in specific locations where clearance compensation is needed, rather than increasing the overall frame height. The recesses are localized to the bottom part of the mono frame, precisely where the cell stack makes contact. This localized approach allows the frame to accommodate press-fitting clearance variations without creating unnecessary wasted space in other areas, maintaining compact overall dimensions while ensuring proper assembly.
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 effective utilization of interior space by reducing unnecessary height in the battery module and allows for precise application of thermally conductive resin, improving heat transfer and module efficiency.
Implementation Method 1
a first and a second thermally conductive resin layers are disposed between a lower part of the cell stack and the module frame
Data Source
AI summary
A battery module includes a cell stack including a plurality of battery cells, and a module frame accommodating the cell stack, a bottom part of the module frame includes a first area, a second area, and a third area in which respective thermally conductive resin layers are formed, and the thermally conductive resin layers of the first area and the second area are each thicker than the thermally conductive resin layer of the third area.