Battery Module Resin Injection Support for Stable Fill Space
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Solution Overview
Problem
Conventional battery modules face challenges in maintaining a consistent space for thermally conductive resin injection, leading to unnecessary weight increase and increased manufacturing costs due to resin overflow caused by component movement under gravity.
Innovation Solution
A battery module design featuring a frame member with an injection hole in the lower surface and an insertion hole in the upper surface for a supporting jig, which prevents component movement and maintains a constant resin injection space, along with an insulating cover to support the battery cell stack and manage resin flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the battery module is turned over for resin injection, then the resin can be injected through the injection hole, but the components move downward by gravity causing inconsistent injection space and resin overflow
Solution Approach 1:
The supporting jig is installed on the upper surface of the frame member before the resin injection process begins. This preliminary action prevents component movement during injection, maintaining consistent injection space and preventing resin overflow while allowing the module to be turned over for injection.
Solution Approach 2:
The supporting jig acts as an intermediary component between the frame member and the battery cell stack. It provides temporary support during the resin injection process, preventing direct contact between components and preventing gravity-induced movement that would cause injection space inconsistency.
2Reliability
If more thermally conductive resin is injected to ensure complete filling, then the injection space is fully filled, but the weight increases unnecessarily
Solution Approach 1:
The checking hole provides visual feedback during the resin injection process. Operators can observe resin flow through the checking hole and stop injection at the precise moment when the injection space is completely filled, preventing both under-filling and over-filling. This feedback mechanism ensures complete filling without unnecessary weight increase.
3Ease of manufacture
If the injection hole is formed in the bottom portion for resin injection, then the resin can be injected, but components move by gravity causing resin overflow through the checking hole
Solution Approach 1:
The supporting jig is installed before resin injection to counteract the gravitational force that would cause components to move and resin to overflow. By applying preliminary anti-action through the supporting structure, the system prevents the harmful effect of resin overflow while maintaining the bottom-positioned injection hole for ease of manufacture.
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
This design ensures appropriate resin injection, reducing manufacturing costs and preventing unnecessary weight increase by maintaining a consistent resin space and stabilizing components during injection.
Implementation Method 1
The thermally conductive resin layer may serve to transfer heat generated from the battery cell stack to the outside of the battery module
Data Source
AI summary
A battery module includes a battery cell stack in which a plurality of battery cells are stacked, and a frame member accommodating the battery cell stack and having an upper surface and a lower surface corresponding to each other, wherein an injection hole for injecting a thermally conductive resin is formed in the lower surface of the frame member, and wherein an insertion hole through which a protrusion of a supporting jig is configured to be passed is formed in the upper surface of the frame member.