Battery Pack Resin Filling Based on Measured Gap Volume

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Solution Overview

Problem

Existing battery pack manufacturing methods fail to accurately set the amount of polymer resin needed to fill the space between a cell stack and a battery pack housing, leading to inefficient cooling and potential overheating or resin overflow issues.

Innovation Solution

A method involving stacking battery cells, coupling them with a U-frame, measuring the volume of the space between a flat plate and the cell stack using fluoroscopic imaging, and applying a polymer resin corresponding to the measured volume, calculated using a formula that accounts for tolerance ranges and area multiplication.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If the injection amount of thermally conductive polymer resin is increased to improve heat dissipation, then thermal conduction function is enhanced, but resin overflow occurs due to excessive injection

Engineering Contradiction:

Improveheat dissipation efficiencyVSAvoidresin overflow

Core Design Contradiction:

TemperatureVSObject-generated harmful factors

Solution Approach 1:

The patent applies preliminary action by pre-calculating the exact volume of polymer resin needed based on the measured space between battery cells and housing before injection. The volume is determined by subtracting the battery cell volume from the housing internal volume, ensuring the resin fills only the necessary space without overflow, while still achieving adequate heat dissipation.

Inventive Principle:

Principle #10Preliminary action

2Loss of substance

If the injection amount of thermally conductive polymer resin is decreased to prevent overflow, then resin waste is reduced, but thermal conduction function becomes insufficient

Engineering Contradiction:

Improveresin wasteVSAvoidheat dissipation efficiency

Core Design Contradiction:

Loss of substanceVSTemperature

Solution Approach 1:

The patent performs preliminary calculation of the precise resin volume required by measuring the housing internal space and battery cell dimensions before injection. This ensures the minimum necessary amount of resin is used to achieve adequate thermal conduction, preventing both waste and insufficient filling.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces the conventional mechanical trial-and-error injection method with a calculation-based system. By using mathematical formulas to determine resin volume based on measured dimensions, the system eliminates the need for excessive injection and subsequent cleanup, optimizing both material usage and thermal performance.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If a fixed amount of polymer resin is used for all battery packs, then manufacturing process is simplified, but heat dissipation efficiency varies due to space variations between battery cells and housing

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidheat dissipation efficiency

Core Design Contradiction:

Ease of manufactureVSTemperature

Solution Approach 1:

The patent applies preliminary measurement and calculation of the specific space volume for each battery pack configuration before resin injection. By determining the exact volume needed based on actual dimensions rather than using a fixed amount, the process ensures optimal heat dissipation for each unique assembly while maintaining manufacturing efficiency through a systematic calculation approach.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent changes the parameter of resin injection amount from a fixed value to a variable determined by actual space measurements. By calculating and adjusting the resin volume based on specific dimensional parameters of each battery pack assembly, the system optimizes heat dissipation efficiency while accommodating variations in assembly tolerances and configurations.

Inventive Principle:

Principle #35Parameter changes

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 ensures the appropriate amount of polymer resin is applied, enhancing thermal conductivity while preventing resin overflow and reducing unnecessary resin usage, thereby improving heat dissipation and maintaining seal integrity.

Implementation Method 1

measuring the volume of the space between a flat plate coupled to the U-frame and the cell stack

Methodology Applied

Scientific EffectFluoroscopic imaging: X-Ray

Implementation Method 2

filling an empty space between the battery cells and a battery pack housing with a thermally conductive polymer resin to remove heat from the battery pack

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentEP3823081B1Battery pack manufacturing method

Publication Date: 2024.05.01 LG ENERGY SOLUTION LTD

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AI summary

Disclosed is a battery pack manufacturing method including (a) stacking battery cells to form a cell stack, (b) coupling the cell stack and a U-frame to each other, (c) measuring the volume of the space between a flat plate coupled to the U-frame and the cell stack, and (d) applying a polymer resin corresponding in amount to the volume measured in step (c).