Battery Module Potting Structure for Low-Viscosity Resin Sealing
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Solution Overview
Problem
Existing battery modules face issues with potting resin leakage due to low viscosity, which complicates the manufacturing process and safety concerns, especially when thermal runaway occurs.
Innovation Solution
A battery module design featuring sequentially decreasing through-holes in the upper and lower cases for resin injection and air discharge, along with sealing members to prevent leakage, and dual injection molding for manufacturing simplification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the viscosity of potting resin is low, then the resin can be rapidly injected and uniformly coats battery cells, but the resin leaks through gaps in the module case
Solution Approach 1:
The case is divided into an upper case and a lower case with separate through-holes for resin injection and air discharge. This segmentation allows controlled resin flow path, enabling low viscosity resin to be injected rapidly without uncontrolled leakage, as each segment (upper/lower case) has dedicated openings for specific functions.
Solution Approach 2:
The through-holes act as intermediary structures that mediate between the resin injection need and leakage prevention requirement. By providing dedicated resin injection through-holes and air discharge through-holes, the system controls the resin flow path, allowing low viscosity resin to flow uniformly to battery cells while preventing uncontrolled leakage through the case structure.
2Reliability
If sealing structures are added to prevent resin leakage, then leakage is prevented, but the manufacturing process becomes more complex
Solution Approach 1:
The case structure merges multiple functions into a single integrated component. The upper and lower cases each incorporate both structural support and sealed through-holes for resin injection and air discharge. This merging eliminates the need for separate sealing components, preventing resin leakage while simplifying the manufacturing process through reduced part count and assembly steps.
3Manufacturing precision
If air discharge pathways are provided during resin filling, then resin fills uniformly, but the case structure becomes more complex
Solution Approach 1:
The through-holes in the upper and lower cases serve multiple functions: they provide structural support for the case, enable resin injection, and facilitate air discharge during filling. This multi-functionality allows uniform resin coating without adding separate air discharge components, maintaining simple case structure while achieving precise uniform coating of low viscosity resin on battery cells.
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 design effectively prevents potting resin leakage and simplifies the manufacturing process, ensuring the resin uniformly coats battery cells even with low viscosity, enhancing safety and efficiency.
Implementation Method 1
a second through-hole (122) configured to allow a potting resin to be injected therethrough
Implementation Method 2
the potting resin can rapidly and uniformly move to respective battery cells
Implementation Method 3
a third through-hole (123) configured to allow air in the upper case (100) and the lower case (200) to be discharged therethrough when the potting resin is filled
Data Source
AI summary
A battery module includes a plurality of battery cells; an upper case comprising a plurality of first side plates to surround a first space and an upper plate connected to upper ends of the first side plates, the upper case being configured to receive upper parts of the battery cells in the first space; and a lower case comprising a plurality of second side plates to surround a second space and a lower plate connected to lower ends of the second side plates, the lower case being configured to receive lower parts of the battery cells in the lower space. The upper plate has a plurality of through-holes.