Battery Module Resin Filling With Leak-Free Distribution Detection
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Solution Overview
Problem
Existing methods struggle with accurately determining the resin injection amount in battery modules, leading to uneven distribution or excess resin waste due to leakage through detection holes.
Innovation Solution
Incorporating a detection agent, such as a contrast agent or coloring material, within the resin layer, and using non-destructive imaging techniques like CT scanning or color change detection to monitor resin distribution, eliminating the need for detection holes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If detection holes are used to monitor resin injection, then resin distribution can be observed, but resin leakage occurs and waste increases
Solution Approach 1:
The patent applies this principle by incorporating a coloring material into the resin composition, which changes the color of the resin as it is injected into the battery module case. This allows visual monitoring of resin distribution through the transparent window without requiring detection holes, thereby preventing resin leakage and waste while maintaining measurement capability.
Solution Approach 2:
The patent extracts the detection function from the case structure by providing a separate transparent window in the lower plate, rather than creating detection holes through which resin can leak. This separation allows monitoring of resin injection while maintaining the integrity and sealing of the case structure.
2Difficulty of detecting and measuring
If detection holes are created in the lower plate, then resin injection state can be detected, but structural integrity is compromised and leakage occurs
Solution Approach 1:
The detection function is extracted from the case body by creating a separate transparent window in the lower plate, distinct from any injection holes. This allows the case structure to remain intact and sealed while still enabling visual detection of resin distribution through the transparent window.
Solution Approach 2:
The transparent window acts as an intermediary that allows optical detection of resin distribution without creating physical openings (detection holes) through which resin could leak. The coloring material in the resin serves as another intermediary that enables detection through the transparent window.
3Manufacturing precision
If excessive resin is injected to ensure full coverage, then complete filling is achieved, but waste increases and removal process is required
Solution Approach 1:
The patent implements feedback by allowing real-time visual monitoring of resin injection through the transparent window using the coloring material. This enables operators to stop injection at the precise moment when complete filling is achieved, preventing over-injection and waste while ensuring complete coverage.
Solution Approach 2:
The coloring material provides visual feedback through color indication, allowing precise control of resin injection volume. Operators can observe the resin front advancing through the case and stop injection exactly when complete filling is achieved, eliminating the need to over-inject and subsequent waste removal processes.
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
Ensures even resin distribution within the battery module, preventing leakage and waste, while maintaining effective thermal conductivity.
Implementation Method 1
wherein when the detection agent is a coloring material, the lower plate includes at least one transparent window that is spaced from the at least one injection hole
Implementation Method 2
wherein the contrast agent is a compound or a complex containing a metal selected from lead, barium or gadolinium
Implementation Method 3
The resin layer may include a thermally conductive resin
Data Source
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AI summary
An exemplary embodiment of the present invention provides a battery module including: a module frame configured to include a lower plate and a side wall constituting an internal space; a battery cell stack disposed in the internal space of the module frame to include a plurality of battery cells that are stacked to be adjacent to each other side by side; and a resin layer disposed between the lower plate and the battery cell stack to include a detection agent, wherein the lower plate includes at least one injection hole.