Insulated Battery Box Coating for Pouch Cell Pack Assembly
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Solution Overview
Problem
Existing battery pack insulation methods using PET films are complex, prone to wrinkles, and affect assembly, compromising the insulation and safety performance.
Innovation Solution
A battery box with a metal frame and insulation coating, where the insulation coating's thickness is calculated to meet specific voltage and current criteria, ensuring effective electrical isolation and simplifying cell assembly, and a battery pack with pouch cells arranged in series, further insulated with an external film for enhanced safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If PET insulation films are used to clad each cell, then insulation performance is improved, but assembly complexity increases and wrinkles occur affecting assembly quality
Solution Approach 1:
The patent merges the insulation function from individual cell-level PET films to a battery pack-level insulation coating applied on the inner surface of the battery box. This single coating structure replaces multiple individual film applications, simplifying the assembly process while maintaining insulation performance between cells and between cells and the metal frame.
Solution Approach 2:
The patent extracts the insulation requirement from each individual cell and consolidates it into a unified insulation coating structure at the battery box level. This eliminates the need to handle and apply separate insulation films to each cell, reducing assembly complexity and preventing wrinkle formation.
2Reliability
If PET insulation films are thermally pressed to side plates and end plates, then insulation is achieved, but the process becomes complicated and time-consuming
Solution Approach 1:
The insulation coating is pre-applied to the inner surface of the battery box during manufacturing, before cell assembly. This preliminary insulation preparation eliminates the need for time-consuming thermal pressing operations during battery pack assembly, as the insulation layer is already in place and ready for cell installation.
Solution Approach 2:
The patent replaces the mechanical thermal pressing process with a coating application process. Instead of using heat and pressure to bond PET films to metal surfaces, an insulation coating is applied to the inner surface, eliminating the complex thermal pressing equipment and process parameters while achieving the same insulation effect.
3Reliability
If insulation films are bonded with pressure-sensitive adhesive, then insulation is provided, but the operation becomes complicated and film wrinkles affect assembly
Solution Approach 1:
The patent applies a homogeneous insulation coating layer directly on the inner surface of the battery box, creating a uniform insulation barrier. This eliminates the heterogeneity introduced by separate PET films with adhesive layers, preventing wrinkles and ensuring consistent insulation quality across all surfaces including side plates and end plates.
Solution Approach 2:
The patent extracts the insulation function from the composite PET film-adhesive structure and implements it as a standalone insulation coating system. This eliminates the need for adhesive bonding operations and the associated quality issues with film wrinkling, as the coating forms an integrated layer without separate bonding interfaces.
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 solution improves insulation efficiency, reduces the risk of insulation failure, and enhances safety performance by simplifying the assembly process and providing effective heat and electrical isolation between cells and the metal frame.
Implementation Method 1
An inner surface of the accommodating cavity is provided with an insulation coating. A thickness D of the insulation coating meets: I≤V×A/(p×D), where p represents a volume resistivity of the insulation coating
Implementation Method 2
providing effective heat and electrical isolation between cells and the metal frame
Data Source
AI summary
The present disclosure provides a battery box, a battery pack with the battery box, and a vehicle. The battery box includes a metal frame. Multiple accommodating cavities for accommodating cells are formed in the metal frame. An inner surface of the accommodating cavity is provided with an insulation coating. A thickness D of the insulation coating meets:D=V×Ap×I.I represents a test current, V represents a test voltage, and p represents a volume resistivity of the insulation coating; D represents a spraying thickness of the insulation coating; and A represents a total spraying area of the insulation coating.