Battery Cap Connector Insulating Coating Against Short Reconnection
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Solution Overview
Problem
Existing battery cap assemblies face safety issues due to reconnection of the pressure relief piece with the connector during external short circuits, particularly when the internal insulating washer thermally melts or abnormally deforms, leading to potential reoccurrence of short circuits and increased risk.
Innovation Solution
Applying an insulating coating comprising inorganic particles, a binding agent, and a solvent to the peripheral and transition parts of the connector, which prevents reconnection by maintaining insulation even after thermal melting or abnormal deformation of the internal insulating washer, and includes a method for applying a single-sided coating using spraying or printing techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the internal insulating washer material is changed from PBT to PFA to increase thermal stability, then the thermal deformation temperature is improved, but the manufacturing cost increases
Solution Approach 1:
An insulating coating is applied to the connector surface before assembly, creating a protective layer that prevents electrical reconnection in advance. This preliminary protective measure eliminates the need to use expensive PFA material throughout the entire washer, allowing cost-effective PBT material to be used while maintaining safety through the pre-applied coating.
Solution Approach 2:
Instead of using expensive high-temperature material for the entire insulating washer, the insulating coating is applied only to specific critical areas of the connector surface where electrical reconnection might occur. This localized approach provides necessary thermal and electrical protection only where needed, reducing overall material costs while maintaining safety.
2Reliability
If the internal insulating washer is used to separate the connector from the pressure relief piece, then the electrical insulation is improved, but the reliability deteriorates due to thermal melting and potential reconnection
Solution Approach 1:
An insulating coating layer is introduced as an intermediary between the connector and the pressure relief piece. This coating acts as an additional protective barrier that prevents direct contact and electrical reconnection even when the internal insulating washer fails due to thermal melting, thereby enhancing overall system reliability.
Solution Approach 2:
The insulating coating provides a preliminary protective barrier that cushions against the harmful effect of electrical reconnection. By having this protective layer in place before thermal failure occurs, the system is prepared to prevent short circuits even when the primary insulating washer fails under high temperature conditions.
3Ease of manufacture
If the transition part of the connector is left uncovered, then the ease of manufacture is improved, but the safety deteriorates due to potential electrical reconnection
Solution Approach 1:
The insulating coating is applied selectively to specific areas of the connector, including the transition part, rather than uniformly across the entire surface. This localized coating approach maintains manufacturing simplicity while providing critical electrical insulation protection where the transition part is most vulnerable to reconnection.
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 insulating coating effectively prevents reconnection between the connector and pressure relief piece, enhancing safety during external short circuits while being cost-effective and controlling coating thickness to avoid insulation degradation.
Implementation Method 1
an insulating coating is applied to the peripheral part and transition part of the connector on one side facing the pressure relief piece
Implementation Method 2
the insulating coating effectively prevents reconnection between the connector and pressure relief piece, enhancing safety during external short circuits
Data Source
AI summary
A cap assembly for a battery, comprising: a connector, the connector comprising a central part, a peripheral part, and a transition part between the former two parts, wherein a current interrupt device is disposed on the central part; a pressure relief piece and electrically connected to the connector via the current interrupt device; and an internal insulating washer, wherein an insulating coating is applied to the peripheral part and transition part of the connector. The insulating coating can prevent reconnection of the connector to the pressure relief piece in the case of an external short circuit and improve the short circuit safety of the battery. The present disclosure further includes a method for making a connector for the cap assembly and to a battery comprising the cap assembly.