Composite Battery Case Material for Moisture and Tracking Resistance
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Solution Overview
Problem
Conventional battery cases made of metal materials are heavy, costly, and require complex assembly processes, with polymer-based cases lacking sufficient moisture transmission resistivity and mechanical strength, and facing challenges in heat dissipation and tracking resistance.
Innovation Solution
A composite material comprising a polymer matrix, an inorganic moisture absorber, a ceramic filler, and a tracking resistance polymer with specific bond energy and carbonaceous residue yield, which provides improved moisture transmission resistivity, heat dissipation, and tracking resistance, allowing for lightweight, cost-effective, and easily molded battery cases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal materials are used for battery cases, then mechanical strength and moisture transmission resistivity are improved, but weight and manufacturing cost increase
Solution Approach 1:
The patent uses composite materials consisting of polymer matrix (polypropylene or polyethylene) combined with inorganic fillers (alumina, silica, titania) and moisture absorbers (zeolite, silica gel, calcium oxide). This composite structure provides mechanical strength comparable to metal while significantly reducing weight, as polymers have lower density than metals while the inorganic fillers enhance structural integrity
Solution Approach 2:
The patent modifies the chemical composition and physical structure of polymer materials by controlling the particle size, content, and distribution of inorganic fillers and moisture absorbers. By optimizing these parameters, the polymer composite achieves enhanced mechanical properties and moisture transmission resistivity that were previously only attainable with metal materials
2Weight of moving object
If polymer-based cases are used, then weight and manufacturing cost are reduced, but moisture transmission resistivity and mechanical strength are insufficient
Solution Approach 1:
The patent develops composite materials where inorganic fillers (alumina, silica, titania) and moisture absorbers (zeolite, silica gel, calcium oxide) are incorporated into the polymer matrix. These inorganic components enhance mechanical strength through reinforcement mechanisms while the polymer base maintains low weight, achieving a balance that pure polymer or pure metal cannot provide
Solution Approach 2:
The patent applies different functional components at different scales within the composite: inorganic fillers provide local structural reinforcement, while moisture absorbers provide localized moisture control. This local quality differentiation allows the material to simultaneously achieve enhanced mechanical properties and moisture transmission resistivity throughout the battery case structure
3Temperature
If inorganic fillers are added to improve heat dissipation, then thermal conductivity is improved, but manufacturing complexity increases
Solution Approach 1:
The patent creates a multi-component composite where inorganic fillers (alumina, silica, titania) with high thermal conductivity are dispersed in the polymer matrix. This composite approach enables heat dissipation enhancement through the intrinsic thermal properties of the inorganic fillers while maintaining processability through conventional polymer processing techniques
Solution Approach 2:
The patent optimizes thermal conductivity by controlling the particle size, shape, and distribution of inorganic fillers within the polymer matrix. By adjusting these parameters, the composite achieves improved heat dissipation while maintaining compatibility with standard manufacturing processes, avoiding the need for complex manufacturing procedures
4Reliability
If tracking resistance polymer with high bond energy is used, then tracking resistance is improved, but manufacturing cost increases
Solution Approach 1:
The patent incorporates tracking resistance polymers (polytetrafluoroethylene, polyvinylidene fluoride, poly(chlorotrifluoroethylene)) into the composite formulation. These polymers with high bond energy (350-500 kJ/mol) provide excellent tracking resistance by forming stable molecular structures that resist electrical breakdown, while their incorporation into the composite allows for cost-effective manufacturing through standard polymer processing
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 composite material significantly enhances moisture transmission resistivity, tracking resistance, and heat dissipation properties, enabling the manufacture of battery cases with desired shapes and sizes, reducing manufacturing costs and time, while ensuring safety and efficiency.
Implementation Method 1
an inorganic moisture absorber; a ceramic filler, graphite, or a combination thereof
Implementation Method 2
a ceramic filler, graphite, or a combination thereof... providing improved moisture transmission resistivity, heat dissipation, and tracking resistance
Implementation Method 3
the tracking resistance polymer includes an average bond energy between an atom forming a main chain and another atom covalently bonded to the atom that forms the main chain in the tracking resistance polymer of about 350 kilojoules per mole (kJ/mol) to about 500 kJ/mol
Data Source
AI summary
A composite including a polymer matrix; an inorganic moisture absorber; a ceramic filler, graphite, or a combination thereof; and a tracking resistance polymer, wherein the tracking resistance polymer includes an average bond energy between an atom forming a main chain and another atom covalently bonded to the atom that forms the main chain of about 350 kJ/mol to about 500 kJ/mol; a carbonaceous residue yield after pyrolysis of less than or equal to about 5 weight percent, based on the amount of the tracking resistance polymer before pyrolysis; or a combination thereof.