Battery Pack Gap Filler Application by Height Tolerance
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Solution Overview
Problem
In battery packs for electric vehicles, improper application of gap fillers between battery modules and the case can lead to reduced heat dissipation, affecting durability and potentially causing battery burning due to uneven height deviations and manufacturing variations.
Innovation Solution
A method for manufacturing battery packs that calculates height tolerances of the seating surface in various regions and determines optimal application amounts of gap filler based on these tolerances, applying additional amounts incrementally to ensure proper heat dissipation and alignment, thereby reducing the overall amount of gap filler needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If gap filler is applied to compensate for height deviations, then heat dissipation is improved, but excessive gap filler application increases material cost and creates uneven surfaces
Solution Approach 1:
The patent applies gap filler with locally optimized thickness in different regions based on measured height deviations. The application amount is determined by calculating the difference between the actual seating surface height and the reference height at each measurement point, ensuring that gap filler is applied only where needed rather than uniformly across the entire surface.
Solution Approach 2:
The patent performs preliminary measurement of the seating surface height at multiple points before applying gap filler. By calculating the height deviations in advance and determining the required gap filler thickness for each region, the application process is optimized to use only the necessary amount of material, preventing both insufficient and excessive application.
2Quantity of substance
If gap filler is not applied in sections with height deviations, then material cost is reduced, but heat dissipation deteriorates leading to battery durability issues
Solution Approach 1:
The patent implements region-specific gap filler application by dividing the seating surface into multiple measurement regions and determining the required gap filler thickness for each region based on local height deviations. This ensures that gap filler is applied with appropriate thickness in areas where height deviations exist, maintaining thermal contact and heat dissipation performance.
Solution Approach 2:
The patent uses measurement data from multiple points on the seating surface to provide feedback on height deviations. This feedback information is used to calculate the precise gap filler application amount for each region, ensuring that the application meets the minimum thickness requirement for effective heat dissipation while avoiding unnecessary material usage.
3Ease of manufacture
If uniform gap filler application is used, then application process is simplified, but heat dissipation becomes uneven due to seating surface height variations
Solution Approach 1:
The patent implements non-uniform gap filler application by determining the required thickness for each region based on measured height deviations from the reference plane. This localized approach ensures that the gap filler compensates for seating surface irregularities, creating a uniform thermal interface despite variations in the underlying surface geometry.
Solution Approach 2:
The patent changes the application parameter (gap filler thickness) based on the measured height deviation parameter. By adjusting the gap filler thickness in each region according to the local height variation, the patent achieves uniform heat dissipation performance across the entire seating surface, transforming a static uniform application process into a dynamic adaptive process.
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 method optimizes gap filler application, enhancing heat dissipation and reducing manufacturing costs by applying the precise amount of gap filler required for each region, improving battery pack durability and preventing overheating.
Implementation Method 1
the gap filler is not applied on a section between the battery modules and the seating surface of the battery case on which the battery modules are seated... heat dissipation from the battery modules may be reduced
Data Source
AI summary
Disclosed is a method for manufacturing a battery pack which has an upper plate configured to have a seating surface, on which battery modules are seated, and a plurality of members configured to separate the seating surface of the upper plate into a plurality of regions. The method includes calculating height tolerances of the seating surface in the respective regions, determining application amounts of the gap filler in the respective regions based on the calculated height tolerances in the respective regions, and applying the determined application amounts of the gap filler in the respective regions.