Battery Module Supply Channel for Thermal Filler Injection
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Solution Overview
Problem
Existing battery arrangements face challenges in achieving effective thermal conductivity between the battery module and the housing, leading to inefficient heat management and potential damage due to uneven filler distribution and high pressures during assembly.
Innovation Solution
The system incorporates a supply channel within the battery module that connects to a cavity in the battery housing, allowing for the introduction and filling of a heat-conducting filler material after the module is positioned, ensuring fluidic connection and optimal distribution for improved thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If filler material is injected into the housing before battery module insertion, then thermal conductivity between battery module and housing is improved, but assembly complexity and positioning precision deteriorate due to premature filling
Solution Approach 1:
The supply channel is pre-integrated into the battery module during manufacturing, but the filler material is not introduced until after assembly. This preliminary preparation of the channel structure enables subsequent easy filling without adding assembly complexity
Solution Approach 2:
The filling operation is extracted from the assembly process and performed as a separate step after the battery module is positioned in the housing. This separation allows positioning to be completed first, then filling to occur without interfering with module placement
2Temperature
If foam material is used to fill air gaps, then heat absorption from battery cells is improved, but manufacturing precision deteriorates due to uneven filler distribution
Solution Approach 1:
The supply channel acts as an intermediary structure that guides the filler material from the injection point to the gap between battery module and housing. This controlled pathway ensures uniform distribution of the foam material throughout the gap area
Solution Approach 2:
The filler material is introduced through the supply channel using fluid injection (foam or liquid that expands). This pneumatic/hydraulic delivery method ensures even distribution of the filling material throughout the cavity, eliminating air pockets and achieving uniform contact
3Stability of the object's composition
If battery module is firmly connected to housing, then structural stability is improved, but thermal conductivity deteriorates due to high pressures during assembly
Solution Approach 1:
The filler material introduced through the supply channel acts as a mediator between the battery module and housing. It fills the gap created by firm connection, maintaining thermal contact without requiring excessive assembly pressure that would compromise the connection
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 approach enhances heat transfer between the battery module and housing, improving cooling efficiency and reducing the risk of damage during assembly by ensuring complete wetting and uniform filler distribution, thus addressing the inefficiencies in existing technologies.
Implementation Method 1
a heat-conducting filler material is introduced after the module is positioned, ensuring fluidic connection and optimal distribution for improved thermal conductivity
Implementation Method 2
a foam material is injected into the housing in order to fill an air gap between a battery cell and the housing and in order to absorb heat from the battery cell
Data Source
AI summary
A system for producing a battery arrangement with at least one battery module and a battery housing. The at least one battery module comprises at least one supply channel which extends in a designated introduction direction through the at least one battery module. The at least one battery module is to be introduced in the introduction direction into the battery housing, positioned in an end position provided for the battery module and firmly connected in this end position to the battery housing. Between a bottom of the at least one battery module and a bottom of the battery housing, at least one cavity is provided, which is to be connected to the at least one supply channel. A filler material is to be filled into the at least one cavity through the at least one supply channel.