Battery Pack Cell Mounting for Easy Cell Replacement
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Solution Overview
Problem
Existing cell-to-pack structures with thermal resin fixation make it difficult to disassemble and replace faulty battery cells, leading to potential damage and the need to discard the entire battery pack.
Innovation Solution
A battery pack design using a combination of thermal resin and TIM pads with adjustable adhesion areas, allowing easy removal of faulty cell units by limiting the curable thermal resin's adhesion to specific areas and incorporating non-curable TIM pads for robust yet detachable fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermal resin is used to fix the cell unit to the base plate, then the adhesion strength and structural integrity are improved, but the ease of disassembly and cell unit replacement deteriorates
Solution Approach 1:
The adhesive system is segmented into two distinct components: thermal resin applied at the perimeter for strong structural bonding, and TIM pad material filling the central area for thermal conduction with controlled adhesion. This segmentation allows each material to perform its primary function while resolving the contradiction between strong fixation and easy disassembly.
Solution Approach 2:
Different adhesive properties are applied to different regions of the cell unit bottom surface. The perimeter region uses thermal resin with high adhesion strength for structural integrity, while the central region uses TIM pad material with lower adhesion strength that facilitates disassembly. This local differentiation of adhesive quality resolves the contradiction by providing both strong bonding and easy removal capabilities in different locations.
2Strength
If thermal resin is applied to fix the cell unit, then the structural integrity is improved, but the heat dissipation performance deteriorates due to additional layer
Solution Approach 1:
The thermal resin and TIM pad material are merged into a single adhesive system that simultaneously provides both structural bonding and thermal conduction functions. The TIM pad material in the central area provides excellent thermal conduction properties while the perimeter thermal resin provides structural integrity, eliminating the need for separate module housing and achieving both goals concurrently.
3Reliability
If the entire battery pack is replaced when one cell fails, then the reliability is maintained, but the loss of time and cost increase significantly
Solution Approach 1:
The faulty cell unit is extracted and replaced independently from the rest of the battery pack. The adhesive system design with TIM pad material in the central area enables easy removal of individual cell units without damaging other components, allowing selective replacement of only the faulty unit rather than the entire battery pack, thus reducing time loss and cost.
4Stability of the object's composition
If cell units are fixed with high adhesion thermal resin, then the structural stability is improved, but the ease of operation for maintenance deteriorates
Solution Approach 1:
The adhesive system is segmented into perimeter thermal resin for structural stability and central TIM pad material for ease of maintenance. This segmentation allows the battery pack to maintain structural integrity during operation while enabling easy disassembly for maintenance activities.
Solution Approach 2:
Different adhesive qualities are applied locally: high-strength thermal resin at the perimeter provides structural stability, while lower-adhesion TIM pad material in the center facilitates maintenance operations. This local quality differentiation resolves the contradiction between structural stability and ease of maintenance.
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
Enables easy replacement of faulty cell units, maintaining and extending the battery pack's lifespan without full disposal, while ensuring effective heat dissipation and structural integrity.
Implementation Method 1
thermal resin may be interposed between the bottom surface of the cell unit, where the battery cells are exposed, and the base plate of the pack case to facilitate the conduction heat dissipation of the cell unit
Implementation Method 2
a thermal interface material (TIM) pad interposed between the bottom surface of each cell unit and the base plate to fix the cell unit
Implementation Method 3
by curing the thermal resin, which can lead to the breakage of the battery cells bonded to the thermal resin
Data Source
AI summary
A battery pack includes a pack case provided with a base plate, a plurality of cell units mounted on top of the base plate, and a thermal resin and a TIM pad are interposed in parallel between the bottom surface of each cell unit and the base plate to fix the cell unit. An adhesion of the TIM pad is small compared to an adhesion of the thermal resin.