Battery Module Frame Pad for Stable Heat Resin Injection
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Solution Overview
Problem
Existing battery modules face challenges in stably applying heat radiating resin for improved cooling performance, leading to inconsistent cooling efficiency and increased manufacturing costs.
Innovation Solution
A battery module design featuring a mono frame with an external expansion controlling pad, which includes two main bodies and two bridges, functions as a dam to ensure stable injection and application of heat radiating resin between the battery cell stacked body and the lower plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If heat radiating resin is injected into the case through an injection hole, then cooling performance can be improved, but the resin may not be stably applied in the designated area leading to inconsistent cooling efficiency and increased manufacturing costs
Solution Approach 1:
The patent applies preliminary action by pre-forming the expansion controlling pad with integrated dams before resin injection. The dams are prepared in advance at specific positions to define the resin filling area, ensuring that when resin is injected, it is automatically confined to the correct region without overflow or insufficient filling, thereby achieving stable and consistent resin application.
Solution Approach 2:
The expansion controlling pad serves as an intermediary element between the injection hole and the case cavity. It includes dams that act as intermediate barriers to control resin flow, preventing direct uncontrolled filling of the case. This intermediary structure ensures precise resin placement and consistent application quality.
2Reliability
If heat radiating resin is injected into the case, then thermal conductivity can be improved, but resin may be excessively applied or applied at lesser amount affecting cooling performance and increasing expense
Solution Approach 1:
The dams are pre-formed as part of the expansion controlling pad structure before resin injection. This preliminary configuration of physical barriers ensures that the resin is automatically confined to the exact required volume, preventing both under-filling and over-filling. This eliminates the need for costly post-processing or material waste, thereby reducing manufacturing expenses while ensuring reliable thermal conductivity.
Solution Approach 2:
The expansion controlling pad with integrated dams performs self-service by automatically regulating the resin filling process. The dams self-confine the resin within the designated area without requiring external control mechanisms or additional processing steps. This self-regulating feature ensures consistent resin application and eliminates material waste, reducing manufacturing costs.
3Manufacturing precision
If additional processes are added to control resin injection, then injection quality can be improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent merges the expansion controlling function and the resin confinement function into a single integrated pad structure. The dams are formed as an integral part of the expansion controlling pad, combining multiple functions (expansion control and resin flow restriction) into one component. This integration eliminates the need for separate confinement structures or additional control processes, maintaining high injection quality while minimizing manufacturing complexity.
Solution Approach 2:
The expansion controlling pad serves multiple functions simultaneously: it controls battery expansion, guides resin injection, and confines resin to the designated area through integrated dams. This multi-functional design eliminates the need for separate components for each function, reducing the overall number of parts and manufacturing steps while maintaining high injection quality.
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 design achieves excellent liquid-injection quality and enhanced cooling performance by preventing resin overflow, reducing manufacturing costs, and improving efficiency without additional processes.
Implementation Method 1
a heat radiating resin provided between the battery cell stacked body and the lower plate
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
A battery module according to an exemplary embodiment of the present invention includes: a battery cell stacked body in which a plurality of battery cells are adjacent each other in parallel and are stacked; a mono frame receiving the battery cell stacked body and including at least one opening opened in a length direction of the battery cell stacked body, and including an upper plate and a lower plate that are perpendicular to a stacked side of the battery cell stacked body and a pair of lateral plates in parallel to the stacked side of the battery cell stacked body; an external expansion controlling pad provided between the battery cell stacked body and the mono frame; and a heat radiating resin provided between the battery cell stacked body and the lower plate, wherein the external expansion controlling pad includes two main bodies covering one side of the battery cell stacked body and provided between the battery cell stacked body and the pair of lateral plates, and two bridges connecting the two main bodies and formed along a side of the battery cell stacked body between the battery cell stacked body and the lower plate.