Battery Cell Insulation Layer for High-Temperature Arc Resistance
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Solution Overview
Problem
Existing battery cell insulation technologies fail to maintain effective insulation performance in high-temperature environments, leading to thermal runaway and safety incidents due to overlapping outer shells, which compromises arc resistance and increases the risk of short-circuits.
Innovation Solution
A battery cell design featuring a first insulation layer with a material damage temperature of at least 400°C and a total thickness of at least 30 μm, combined with a second insulation layer for enhanced water repellency, to maintain insulation effectiveness and prevent thermal damage, while optimizing energy density and manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the insulation layer thickness is increased to maintain insulation performance in high-temperature environments, then the arc resistance and insulation effectiveness are improved, but the energy density of the battery cell deteriorates
Solution Approach 1:
The patent applies parameter changes by specifying precise thickness ranges (30-200 μm) and material damage temperature thresholds (≥400°C) for the insulation layer. This quantitative approach optimizes the balance between insulation performance and energy density, ensuring the insulation layer is thick enough to prevent thermal runaway while minimizing space occupation to maintain high energy density.
Solution Approach 2:
The patent employs composite materials by requiring the insulation layer to be composed of multiple materials with complementary properties: at least one material with damage temperature ≥400°C for thermal resistance, and at least one material with water absorption rate <1% for moisture protection. This composite structure achieves superior insulation performance without excessive thickness, thereby preserving energy density.
2Object-affected harmful factors
If the material damage temperature of the insulation layer is increased to withstand thermal runaway, then the arc resistance capability is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent simplifies manufacturing by establishing a clear parameter threshold for material selection (damage temperature ≥400°C). This single quantitative criterion guides material selection and quality control, making the manufacturing process more standardized and less complex while ensuring sufficient arc resistance capability.
Solution Approach 2:
The patent extracts the essential requirement for arc resistance by focusing on the material damage temperature parameter, separating this critical function from other insulation properties. By identifying and specifying this key parameter independently, the patent simplifies the manufacturing process while maintaining effective arc resistance protection.
3Duration of action of stationary object
If the water absorption rate of the insulation layer is decreased to prevent moisture-related failures, then the lifecycle insulation performance is improved, but the material selection range is reduced
Solution Approach 1:
The patent uses parameter changes by setting a specific water absorption rate threshold (<1%) as a selection criterion for insulation materials. This quantitative parameter guides material selection to ensure long-term insulation performance while maintaining a reasonable material selection range through clear, measurable specifications.
Solution Approach 2:
The patent resolves the material selection constraint by employing composite materials that simultaneously satisfy both requirements: low water absorption (<1%) and high damage temperature (≥400°C). By combining materials with complementary properties, the patent achieves improved lifecycle performance while maintaining versatility in material selection.
Data Source
AI summary
Provided are a battery cell, battery, and electrical device. The battery cell includes an outer shell and an insulating component. The insulating component covers at least a portion of an external surface of the outer shell. The insulating component includes at least one layer of a first insulation layer, wherein a material damage temperature of each layer of the first insulation layer is T, and a total thickness of at least one layer of the first insulation layer is L1. It satisfies T≥400° C. and L1≥30 μm. The first insulation layer of the insulating component possesses a higher material damage temperature and the total thickness of all the first insulation layers in the insulating component is thicker, so that the insulation properties of the insulating component can be maintained to be effective for a long period of time in a high-temperature environment.