Aluminum Battery Case with Insulative Polymer Coating
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Solution Overview
Problem
Lithium secondary batteries face safety concerns due to combustible materials and risk of overheating or explosion, and the assembly process is complicated by the need for conductive connections that can lead to short circuits and corrosion, requiring improved insulation and corrosion resistance.
Innovation Solution
A battery cell with an aluminum or aluminum alloy case coated with an electrically insulative polymer material to enhance durability, corrosion resistance, and manufacturing efficiency, eliminating the need for additional components and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a battery case made of conductive metal is used to receive battery parts, then the battery case provides structural support and durability, but it may cause short circuits when contacting other battery parts and exhibits poor corrosion resistance
Solution Approach 1:
The battery case is constructed as a composite structure with a conductive metal base layer providing structural support and durability, covered by an electrically insulative polymer coating layer that prevents short circuits and corrosion. This composite approach allows simultaneous achievement of mechanical strength and electrical insulation properties.
Solution Approach 2:
The battery case applies different material properties to different functional requirements: the metal base layer provides mechanical strength where needed, while the polymer coating layer provides electrical insulation and corrosion resistance where required. Each layer performs its specific function optimally.
2Reliability
If safety elements like PCM are electrically connected to battery cell terminals via conductive nickel plates using welding or soldering, then electrical connection is established, but the assembly process becomes complicated and requires multiple parts
Solution Approach 1:
The battery case integrates multiple functions into a single component: it provides structural support, electrical insulation through polymer coating, corrosion resistance, and simplified mounting for safety elements. This merging eliminates the need for separate conductive nickel plates and reduces assembly complexity.
Solution Approach 2:
The battery case is designed as a multi-functional component that simultaneously performs mechanical support, electrical insulation, corrosion protection, and safety element mounting. This universal design reduces the total number of parts needed in the battery assembly.
3Reliability
If multiple parts are used to maintain electrical connection and isolation for safety elements, then electrical safety is ensured, but the receiving space for the battery cell is reduced
Solution Approach 1:
The battery case combines electrical isolation and structural support functions into a single integrated component, eliminating the need for separate isolation parts. This integration maximizes the receiving space while maintaining electrical safety.
4Ease of manufacture
If a conventional battery cell assembly method is used, then manufacturing is straightforward, but the outer surface of the battery case is susceptible to corrosion and wear
Solution Approach 1:
The battery case uses a composite structure with a metal base layer for structural integrity and a polymer coating layer that provides corrosion and wear resistance. This composite approach maintains ease of manufacturing while protecting against environmental degradation.
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 protective coating layer improves corrosion resistance, wear resistance, and insulation, reducing the risk of short circuits and enhancing the battery's capacity while simplifying the assembly process and eliminating the need for additional components.
Implementation Method 1
a protective coating layer applied to at least a portion of an outer surface of the battery case, the protective coating layer containing an electrically insulative polymer material
Implementation Method 2
improve insulativity and capacity of the battery cell and completed the present invention... improving corrosion resistance, wear resistance, and insulativity of the battery case
Data Source
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AI summary
Disclosed herein is a battery cell including an electrode assembly of a cathode/separator/anode structure, the electrode assembly being impregnated with an electrolyte, the electrode assembly being chargeable and dischargeable, a battery case in which the electrode assembly is mounted, the battery case being made of aluminum or an aluminum alloy, and a protective coating layer applied to at least a portion of an outer surface of the battery case, the protective coating layer containing an electrically insulative polymer material.