Battery Thermal Interface Sealing and Filling Method
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Solution Overview
Problem
Current methods for producing thermal interfaces in motor vehicle batteries face challenges such as high assembly forces, long process times, material overfilling leading to waste and increased vehicle weight, and poor thermal performance due to manufacturing tolerances and uneven gap filling.
Innovation Solution
A method involving a battery module with inlet and outlet channels for thermally conductive material, combined with a flexible linear seal that compresses to fill a cavity between the module and a heat transfer surface, allowing for complete and bubble-free filling without pre-applying the material, thus reducing assembly forces and accommodating dimensional and positional fluctuations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermal interface material is applied before assembly to ensure complete gap filling, then thermal performance is improved, but assembly forces increase and process time lengthens
Solution Approach 1:
The patent applies preliminary action by pre-applying the thermal interface material to the heat transfer surface before assembly. This ensures the material is already in position to fill gaps completely, eliminating the need for high compression forces during assembly. The material is applied in advance at optimal conditions, then the components are assembled without requiring excessive force to compress the material into place.
2Reliability
If thermal interface material is applied before assembly to ensure complete gap filling, then thermal performance is improved, but process time increases
Solution Approach 1:
The thermal interface material is applied to the heat transfer surface in advance, allowing for optimized application conditions and material distribution. This preliminary action enables faster assembly since the material is already positioned correctly, eliminating the need for slow compression processes during final assembly.
3Reliability
If thermal interface material is overfilled to accommodate maximum gap dimensions, then gap filling reliability is improved, but material usage and cost increase
Solution Approach 1:
The patent applies local quality by distributing the thermal interface material specifically where gaps are needed, rather than uniformly overfilling all areas. The material is applied to match the actual gap distribution pattern, providing reliable filling only in regions where gaps exist, thereby reducing unnecessary material usage while maintaining gap filling reliability.
4Reliability
If thermal interface material is overfilled to accommodate maximum gap dimensions, then gap filling reliability is improved, but vehicle weight increases
Solution Approach 1:
The thermal interface material is applied locally to areas where gaps actually exist, rather than uniformly overfilling the entire heat transfer surface. This targeted approach maintains reliable gap filling in critical areas while minimizing the total amount of material used, thereby reducing the added vehicle weight.
5Strength
If pressing is performed slowly to keep forces low and avoid damage, then structural integrity is improved, but process time increases
Solution Approach 1:
The thermal interface material is applied to the heat transfer surface before assembly, allowing it to be positioned optimally without requiring high compression forces during the assembly process. This preliminary positioning eliminates the need for slow, forceful pressing that would be required if material were applied during assembly, thereby maintaining structural integrity while significantly reducing process time.
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 enables efficient, quick, and homogeneous filling of thermal interfaces, reducing material usage and weight, while ensuring effective heat transfer and minimizing environmental impact by optimizing the filling process and reducing material waste.
Implementation Method 1
compressing the seal so that it encloses a cavity within the gap between the battery module side and the heat transfer surface
Implementation Method 2
applying at least one flexible linear seal to the battery module side or the heat transfer surface
Implementation Method 3
filling the cavity with the thermal conductivity material through the inlet opening, the thermal conductivity material introduced into the cavity forming the thermal interface
Data Source
Figure 1~2
Figure 3
Figure 4~7
AI summary
The invention relates to a method for producing a thermal interface in a battery (10) for a motor vehicle, comprising the steps of: providing at least one battery module (12) with at least one inlet channel (14) which opens into at least one inlet opening (18) for a thermally conductive material (46) on a battery module side (16), and with at least one outlet channel (20) which opens into at least one outlet opening (22) for the thermally conductive material (46) on the battery module side (16); providing a receiving structure (24) with a receiving area having a heat transfer surface (26) for receiving the battery module (12) in an intended installation position in which a gap (34) exists between the battery module side (16) and the heat transfer surface (26); applying at least one flexible linear seal (42) to the battery module side (16) or the heat transfer surface (26);Mounting the battery module (12) in its intended installation position by compressing the seal (42), so that it encloses a cavity (44) within the gap (34) between the battery module side (16) and the heat transfer surface (26); filling the cavity (44) with the thermal conductivity material (46) through the inlet opening (18), the thermal conductivity material (46) introduced into the cavity (44) forming the thermal interface. The invention further relates to a battery (10) for a motor vehicle.