Battery Pack Adhesive Injection for Thermal and Moisture Protection
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Solution Overview
Problem
Conventional battery packs lack effective methods to securely integrate adhesive materials within their internal cavities, which can lead to gaps that affect thermal conductivity and moisture protection, potentially reducing the battery's performance and lifespan.
Innovation Solution
A battery pack assembly with an injection port system that directs adhesive material, such as thermally conductive silicone encapsulant, into the internal cavity to cover battery cells and electronics, forming a continuous layer that enhances thermal conduction and moisture resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive material is applied in conventional battery packs, then bonding strength is improved, but gaps remain that reduce thermal conductivity and moisture protection
Solution Approach 1:
The patent uses injection molding technology to inject adhesive material in liquid form into the battery pack housing, allowing the material to flow into all gaps and voids between components. This hydraulic approach ensures complete filling of the cavity, eliminating air pockets and ensuring uniform adhesive distribution, which simultaneously achieves strong bonding and continuous thermal/moisture protection pathways.
Solution Approach 2:
The patent changes the physical state of the adhesive material from solid/pre-formed to liquid/injected form. By injecting the adhesive in liquid state and allowing it to cure in situ, the material can adapt to the exact geometry of the cavity and bond surfaces, eliminating gaps while maintaining bonding strength. This parameter change enables the adhesive to conform to complex geometries and fill all voids.
2Reliability
If adhesive material is injected into the internal cavity, then thermal performance and moisture protection are improved, but device complexity increases due to injection port requirements
Solution Approach 1:
The injection port is designed to serve multiple functions: it acts as the injection channel for adhesive material during manufacturing, and after curing, it becomes part of the sealed structure contributing to moisture and thermal protection. This multi-functionality reduces the need for separate components, as the injection port structure serves both as a manufacturing feature and a functional element of the final product.
3Temperature
If adhesive material covers battery cells and electronics, then thermal conduction is enhanced, but manufacturing precision requirements increase
Solution Approach 1:
The injection molding process uses controlled liquid flow to distribute adhesive material uniformly throughout the cavity. By controlling injection pressure, flow rate, and curing parameters, the process achieves consistent adhesive distribution without requiring extremely tight tolerances on component positioning. The liquid adhesive flows to fill voids and conform to surfaces, compensating for minor manufacturing variations.
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 improves thermal performance and cycle life of the battery pack by ensuring better heat dissipation and protects against moisture ingress, thereby extending the battery's operational time and durability.
Implementation Method 1
The fluid includes thermally conductive silicone encapsulant
Implementation Method 2
a layer comprising adhesive material is positioned within the internal cavity between a portion of the battery cells and a portion of the battery electronics
Data Source
AI summary
A battery pack assembly includes a housing having a plurality of sides and defining an internal cavity, a plurality of battery cells received in the internal cavity, and battery electronics received in the internal cavity. A battery pack interface is supported by the housing and connectable to a device. An injection port is supported by the housing. The injection port includes one or more channels positioned on one or more of the sides of the housing. Each channel connects the internal cavity to an exterior of the battery pack. The injection port is configured to direct a fluid comprising adhesive material from the exterior of the battery pack into the internal cavity. The fluid is configured to cover at least one of a portion of the battery cells and a portion of the battery electronics.