Battery Pack Filling Structure for Heat Insulation and Rigidity

The patent applies local quality by using different filling materials in different regions of the battery pack. Specifically, it uses a hard filling material (such as foam or resin) in regions requiring rigidity support, and a soft filling material (such as elastic foam) in regions requiring vibration absorption. This localized differentiation resolves the contradiction by providing rigidity where needed while maintaining ease of assembly through material properties that naturally fill spaces.

The patent employs composite materials by combining multiple filling materials with different properties within the same battery pack. The combination of hard filling material and soft filling material creates a composite structure that simultaneously achieves rigidity (from the hard material) and vibration resistance (from the soft material), while both materials being injection-moldable maintains ease of assembly through a single manufacturing process.

The patent applies local quality by strategically placing thermal conductivity-enhancing filling material in regions where heat transfer is critical, such as near heat-generating battery cells. The filling material is selected or treated to have high thermal conductivity, creating localized heat dissipation pathways without requiring empty spaces, thus maintaining ease of assembly while improving heat transfer.

The patent changes the thermal parameter of the filling material by selecting materials with high thermal conductivity or by treating the filling material to enhance its thermal properties. This parameter change allows the filling material to actively participate in heat dissipation rather than merely occupying space, resolving the contradiction between ease of assembly and heat transfer efficiency.

The patent applies self-service by using injection molding technology that allows the filling material to automatically fill and adapt to the available spaces within the battery pack case. The material flows into all empty spaces and solidifies in place, eliminating the need for pre-formed inserts or complex assembly steps. This self-filling capability simplifies the overall structure and assembly process while achieving the desired rigidity enhancement.

The patent employs universal filling material that simultaneously provides multiple functions: structural support for rigidity, vibration absorption through elastic properties, and heat dissipation through thermal conductivity. This multi-functional filling material eliminates the need for separate components for each function, reducing device complexity while achieving rigidity improvement.

The patent merges the functions of multiple filling materials into a single injection molding process. By formulating a composite filling material that combines hard and soft phases, or by sequentially injecting different materials in one automated process, the patent achieves the thermal and structural benefits of multiple materials without requiring separate assembly steps. This merging approach reduces manufacturing complexity while maintaining improved heat transfer and rigidity.

The patent uses composite filling materials that can be processed together through injection molding. The composite formulation allows different material phases (hard and soft) to be combined in a single material feed or sequentially injected in one automated operation, achieving multi-functionality without increasing manufacturing complexity. The composite material structure provides both thermal management and structural support properties simultaneously.