Battery Cell Housing Surface-Energy Layout for Insulating Film Bonding
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Solution Overview
Problem
The reliability of battery cells is compromised due to insufficient bonding force between the adhesive layer and the housing, leading to a high risk of the insulating film detaching, which can cause electrolyte leakage and internal short-circuiting.
Innovation Solution
The housing is designed with a first part having a lower surface energy and a second part with a higher surface energy, where the insulating film is connected to the second part via an adhesive layer, enhancing the bonding force and reducing the risk of detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the housing uses a material with low surface energy, then the manufacturing cost is reduced, but the bonding force between the adhesive layer and the housing is insufficient
Solution Approach 1:
The housing is designed with a first part (main body) made of low surface energy material for cost efficiency, and a second part (bonding surface) with high surface energy for strong adhesive bonding. This local differentiation allows the housing to achieve both low manufacturing cost and high bonding reliability.
Solution Approach 2:
The housing combines two different materials: a base material (first part) with low surface energy and a coating material (second part) with high surface energy. This composite structure enables the housing to simultaneously achieve cost-effectiveness and strong adhesive bonding capability.
2Reliability
If the surface energy of the housing is increased to improve bonding force, then the reliability is improved, but the manufacturing cost increases
Solution Approach 1:
Instead of increasing the surface energy of the entire housing, only the second part (bonding surface) that contacts the adhesive layer is made of high surface energy material. This localized approach achieves the necessary bonding reliability while minimizing the increase in manufacturing cost.
Solution Approach 2:
The high surface energy material is applied only to the extent necessary for reliable bonding (the second part), rather than the entire housing. This partial application achieves the required bonding force while controlling manufacturing costs.
3Device complexity
If the adhesive layer is applied to the first part, then the manufacturing process is simpler, but the insulating film may detach due to insufficient bonding
Solution Approach 1:
The adhesive layer is specifically applied to the second part (bonding surface) rather than the entire housing. This localized application ensures reliable bonding where needed while keeping the manufacturing process relatively simple.
Solution Approach 2:
The second part acts as an intermediary between the first part (housing body) and the adhesive layer. It provides the high surface energy interface necessary for strong bonding while being connected to the main housing structure.
Data Source
AI summary
A battery cell includes a housing, a first insulating film, and an adhesive layer. The housing includes a first part and a second part, the first part is connected to the second part, and a surface energy of the second part is greater than a surface energy of the outer surface of the first part. The first insulating film covers at least one part of the housing. The adhesive layer is disposed between the second part and the first insulating film and configured to connect the first insulating film to the second part.