Modular Injection Nozzle for Uniform Battery TIM Coating
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Solution Overview
Problem
Conventional rechargeable battery housings with varying surface areas face challenges in uniformly applying thermal interface material due to the limitations of a single injection nozzle.
Innovation Solution
A modular injection nozzle system comprising a main nozzle and detachable sub-nozzles, allowing for adjustable configuration based on the surface area of the rechargeable battery housing, with each nozzle segment having a tapered design to enhance material flow and minimize leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single injection nozzle is used to spray thermal interface material on rechargeable battery housings with various surface areas, then the device complexity is reduced, but the manufacturing precision and uniformity of material application deteriorate
Solution Approach 1:
The injection nozzle is divided into a main nozzle and multiple sub-nozzles. The main nozzle receives thermal interface material and distributes it to several sub-nozzles, which then spray the material onto different sections of the battery housing surface. This segmentation allows a single nozzle system to effectively cover various surface areas while maintaining uniform material application across different sections.
2Area of stationary object
If the number of sub-nozzles is increased to cover larger surface areas, then the coverage area is improved, but the device complexity increases
Solution Approach 1:
The main nozzle is designed with multiple coupling portions that can connect to different numbers and configurations of sub-nozzles. This universal design allows the same main nozzle to serve multiple functions by adapting to different battery housing sizes and shapes, simply by changing the number of attached sub-nozzles without redesigning the entire system.
Solution Approach 2:
The nozzle system allows dynamic configuration where sub-nozzles can be selectively coupled or decoupled from the main nozzle based on the specific battery housing size. This dynamic adaptability enables the system to optimize coverage area while maintaining manageable complexity by only activating the necessary number of sub-nozzles for each application.
3Manufacturing precision
If the flow cross-sectional area is reduced from inflow hole to injection hole, then the spray precision is improved, but the material flow rate decreases
Solution Approach 1:
The material flow is segmented into multiple parallel pathways through the main nozzle body to multiple sub-nozzles. While each individual pathway has a reduced cross-sectional area for precision spraying, the total flow rate is maintained by having multiple concurrent flow paths, thus achieving both precision and productivity.
Solution Approach 2:
Multiple sub-nozzles are combined into a single integrated system controlled by one main nozzle. The material flow is divided among sub-nozzles for precise individual spraying, but the combined output of all sub-nozzles achieves the total material application rate needed for productive manufacturing.
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
The system efficiently applies thermal interface material to various surface areas, reducing process time and cost by optimizing nozzle configuration and minimizing material loss, thereby improving productivity in battery manufacturing.
Implementation Method 1
a main nozzle (100) that receives a thermal interface material (20) from the outside and sprays the thermal interface material (20) to a surface (11) of a rechargeable battery housing (10)
Implementation Method 2
a plurality of sub nozzles (200, 210, 220, 230, 240) that are coupled to the main nozzle (100) in a lateral direction, receives the thermal interface material (20) from the main nozzle (100), and sprays the thermal interface material (20) to the surface (11) of the rechargeable battery housing (10)
Implementation Method 3
A width of the lateral direction of an inner space of the main nozzle may be reduced as it goes from the inflow hole through the main nozzle body to the injection hole
Data Source
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AI summary
An injection nozzle (1000) that sprays a thermal interface material to a surface of a rechargeable battery housing includes: a main nozzle (100) that receives the thermal interface material from the outside and sprays the thermal interface material to the surface of the rechargeable battery housing; and a plurality of sub nozzles (200) that are coupled to the main nozzle (100) in a lateral direction, receives the thermal interface material from the main nozzle (100), and sprays the thermal interface material to the surface of the rechargeable battery housing.