Cavity Filling Pressure Control to Prevent Battery Module Overflow
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Solution Overview
Problem
Existing methods for injecting thermally conductive filling materials into battery modules result in the material swelling out of the cavity at the end of the injection process, which is undesirable.
Innovation Solution
A method and device that utilize a metering device to control the flow rate of the filling material based on pressure measurements, adjusting the flow rate at specific points during the injection process to prevent overfilling by using pressure sensors to detect changes in injection pressure and adjusting the flow rate accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the filling material is injected into the cavity using conventional injection methods, then the cavity can be filled with the material, but the filling material swells out of the battery module at the end of the injection process
Solution Approach 1:
The patent implements a feedback control system where a pressure sensor continuously monitors the injection pressure during the filling process. The control unit receives real-time pressure data and adjusts the metering device's flow rate accordingly. When the pressure reaches a predetermined threshold indicating the cavity is sufficiently filled, the system automatically reduces or stops the flow rate to prevent overfilling and swelling of the material outside the module.
Solution Approach 2:
The patent employs dynamic adjustment of the flow rate during the injection process rather than maintaining a constant flow rate. The metering device is controlled to vary the flow rate based on real-time pressure feedback, allowing the system to adapt to changing cavity fill conditions. This dynamic control enables precise filling while preventing material swelling at the end of injection.
2Temperature
If a highly viscous, heavily filled filling material is used to achieve thermal coupling, then the thermal conductivity requirement is met, but the material becomes highly abrasive and has high density
Solution Approach 1:
The patent changes the physical parameters of the filling material by reducing its viscosity and solid content compared to conventional materials. The formulation is modified to use less dense and less abrasive components while maintaining adequate thermal conductivity through optimized composition. This parameter change allows the material to be processed more easily and reduces harmful effects during injection and handling.
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
Prevents the filling material from escaping the cavity after the injection process, ensuring precise filling without overfilling.
Implementation Method 1
a first pressure sensor is provided which serves to determine an injection pressure of the filling material during the injection process
Implementation Method 2
a first metering device with a controllable flow rate is provided, which serves to convey the filling material to the applicator
Data Source
AI summary
A method for applying a fluid filling material into a cavity of a component including conveying the filling material by at least one metering device with a predetermined flow rate to an applicator, injecting the filling material by the applicator into the cavity of the component establishing an injection pressure, measuring the injection pressure by means of a pressure sensor, determining a first pressure increase of the injection pressure, and reducing the flow rate of the metering device at a first switchover point at the first pressure increase of the injection pressure.