Battery Pack Resin Test Jig for Uniform Shear Specimens
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Solution Overview
Problem
Existing methods fail to uniformly apply and control the amount, area, and thickness of thermally conductive resin between battery cells and a top plate in battery packs, making it difficult to measure shear force effectively.
Innovation Solution
A jig for manufacturing specimens that ensures consistent application of thermally conductive resin by using a jig body with specific geometries and rotational features to fix and position test pieces, allowing for controlled addition and removal of resin, and subsequent attachment of a metal plate for shear force measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods are used to apply thermally conductive resin between battery cells and top plate, then the resin can be applied to fill the space, but the amount, area, and thickness of resin application cannot be uniformly controlled
Solution Approach 1:
A jig is introduced as an intermediary tool to control the application of thermally conductive resin. The jig includes a support plate with through-holes positioned at specific locations, and a press plate that applies pressure to extrude resin through these holes. This intermediary device enables precise control over resin application amount, area, and thickness, resolving the contradiction between manufacturing precision and ease of manufacture.
Solution Approach 2:
The jig is prepared in advance with through-holes positioned at predetermined locations where resin needs to be applied. The support plate and press plate are configured before the bonding process, establishing the exact pattern and quantity of resin application. This preliminary setup ensures uniform resin distribution without requiring complex real-time control during the manufacturing process.
2Measurement precision
If samples are used to replace battery case and top plate for shear force testing, then shear force can be measured, but it is difficult to uniformly apply and control the thermal conductive resin
Solution Approach 1:
The jig serves as a mediator that enables both uniform resin application and accurate shear force measurement. By using the jig to apply resin through controlled extrusion via through-holes, the invention ensures consistent resin application on test samples while maintaining the ability to measure shear force between the battery cell and top plate.
Solution Approach 2:
The through-holes in the support plate create localized resin application points at specific positions between the battery cell and top plate. This local quality approach ensures that resin is applied precisely where needed with controlled amount and thickness, enabling both uniform application and accurate shear force measurement at the bonding interface.
3Temperature
If thermally conductive resin is injected to fill the space between battery cell stack and top plate, then heat dissipation is improved, but the shear force between components cannot be effectively measured
Solution Approach 1:
The invention extracts the measurement function from the actual battery pack by creating a separate test sample configuration. The jig enables preparation of test samples with controlled resin application, allowing shear force measurement to be performed on representative samples without requiring measurement capabilities within the complete battery pack assembly. This extracted approach maintains heat dissipation benefits while enabling precise shear force measurement.
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
Enables the production of standardized specimens with uniform resin application, facilitating accurate measurement of shear force without disassembling the battery pack, thereby improving heat dissipation and safety.
Implementation Method 1
A thermally conductive resin is injected into a battery pack including a plurality of battery cells in order to increase heat dissipation of the plurality of battery cells
Data Source
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AI summary
Disclosed are a jig for manufacturing specimen that checks the shear force of a thermally conductive resin injected between a battery cell stack accommodated in a battery pack and a top plate added so as to cover an upper part of the battery cell stack, the jig including a jig body including an upper end portion disposed so as to be perpendicular to a longitudinal direction of a test piece and a first lower end portion and a second lower end portion extending downward from both ends of the upper end portion, respectively, wherein the first lower end portion and the second lower end portion are spaced apart from each other such that the distance therebetween is greater than the width of the test piece, and a specimen manufacturing method using the same.