Static Mixer Attachment With Pressure Sensing for Gap Filling
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Solution Overview
Problem
The challenge is to reliably fill a filler material, such as thermal paste, into a gap between battery cells and a housing in electric or hybrid vehicles, where varying installation tolerances and pressure limitations restrict the volumetric flow rate, necessitating a solution to optimize the filling process while minimizing information loss about pressure data.
Innovation Solution
An attachment element for a static mixer that includes a flow channel with an inlet and outlet opening, a fastening unit for secure attachment to the mixer's injection tip, and a receiving opening for a pressure sensor to monitor and control the volume flow, allowing for precise regulation of the filler material injection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the volumetric flow rate of filler material is increased to optimize cycle time, then productivity is improved, but the pressure exceeds the maximum permissible pressure limit
Solution Approach 1:
The patent implements dynamic control of the volumetric flow rate based on real-time pressure feedback. The control device adjusts the flow rate during the injection process, allowing higher flow rates when pressure is low and reducing flow rate when pressure approaches the maximum permissible limit, thereby optimizing productivity while respecting pressure constraints
Solution Approach 2:
The patent employs a pressure sensor that provides real-time pressure data to a control device. This feedback mechanism enables the control device to monitor pressure conditions and adjust the volumetric flow rate accordingly, ensuring that pressure remains within permissible limits while maximizing the filling speed and productivity
2Measurement precision
If a pressure sensor is integrated into the battery module to minimize information loss, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent introduces an attachment element as an intermediary component that houses the pressure sensor. This attachment element couples to the static mixer and positions the pressure sensor in close proximity to the injection opening, enabling accurate pressure measurement without permanently modifying the battery module structure. The attachment element serves as a mediator between the measurement need and the system architecture
Solution Approach 2:
The patent segments the pressure measurement function into a separate, removable attachment element rather than integrating it permanently into the battery module. This segmentation allows the pressure sensor to be positioned optimally for accurate measurement while keeping the battery module structure simple and unchanged. The attachment element can be easily coupled and decoupled, maintaining system modularity
3Measurement precision
If the pressure sensor is positioned close to the injection opening to minimize information loss, then measurement precision is improved, but ease of manufacture decreases
Solution Approach 1:
The attachment element serves multiple functions: it houses the pressure sensor, provides a mounting interface for the static mixer, and positions the sensor optimally near the injection opening. This multi-functionality consolidates several requirements into a single component that can be manufactured and assembled relatively easily, despite the precise positioning requirements
Data Source
AI summary
An attachment element for a static mixer and an attachment system with such an attachment element, the static mixer, and a pressure sensor. The attachment element has a flow channel with an inlet opening and an outlet opening arranged opposite the inlet opening in a longitudinal direction of the flow channel and designed as an injection nozzle. The attachment element is designed to be fastened at an inlet side having the inlet opening by a fastening unit of the attachment element on top of an injection tip of the static mixer. Furthermore, the attachment element has a receiving opening for the pressure sensor. The receiving opening extends from an exterior side of the attachment element to an opening in a subsection of a channel wall of the flow channel.