Battery Cell Cladding With Crosslinked Insulating Adhesive Film
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Solution Overview
Problem
Current battery cell insulation methods, such as using pressure-sensitive adhesive tape, are insufficient in terms of bond strength, particularly in harsh vehicle environments, leading to potential battery short-circuiting and instability.
Innovation Solution
A method involving a crosslinkable adhesive film with a carrier, specifically an electrically insulating carrier, is applied to the battery cell, where the adhesive film is crosslinked using radiation, providing a strong bond exceeding 5 MPa by adhering to the cell's sides and top, enhancing stability and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pressure-sensitive adhesive tape is used for battery cell insulation, then the insulation function is provided, but the bond strength is insufficient (lower than 1 MPa) and reliability is inadequate for harsh vehicle environments
Solution Approach 1:
The adhesive is transformed from a simple pressure-sensitive adhesive to a crosslinkable adhesive system. The chemical structure is modified to include crosslinkable functional groups (epoxy, vinyl, or isocyanate groups) that enable post-application crosslinking, fundamentally changing the adhesive's performance parameters from <1 MPa to >5 MPa bond strength while maintaining environmental stability.
Solution Approach 2:
The adhesive film is constructed as a composite material system comprising a carrier (PET, PP, or PI) combined with a crosslinkable adhesive layer containing specific functional groups. This composite structure provides both the mechanical properties of the carrier and the chemical reactivity of the crosslinkable adhesive, achieving superior bond strength and environmental resistance that neither component could provide alone.
2Reliability
If stronger adhesives are used to improve bond strength, then assembly reliability increases, but the complexity of the adhesive application process and crosslinking requirements increases
Solution Approach 1:
The adhesive is applied in its uncrosslinked state during the assembly process, allowing for easy application and repositioning. The crosslinking reaction is then initiated afterward through UV irradiation, heat treatment, or moisture exposure, separating the application phase from the curing phase and simplifying the overall process.
Solution Approach 2:
The traditional mechanical bonding or simple pressure-sensitive adhesion is replaced with a chemical crosslinking mechanism. This substitution enables the adhesive to form covalent bonds with the battery cell surfaces, achieving superior bond strength without requiring complex mechanical fastening systems or multi-step application processes.
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 method significantly increases the bond strength of the adhesive film with the battery cell, ensuring structural integrity and reliability, even in challenging environmental conditions, thereby preventing short-circuiting and ensuring safe operation.
Implementation Method 1
the adhesive film is crosslinked using radiation, providing a strong bond exceeding 5 MPa
Data Source
AI summary
Methods clad battery cells and comprise adhesively bonding at least one crosslinkable adhesive layer of a adhesive film and the at least one bottom side of a battery cell, adhesively bonding the at least one crosslinkable adhesive layer of the adhesive film and at least two first side walls of the battery cell, adhesively bonding the at least one crosslinkable adhesive layer of the adhessive film and at least two second side walls of the battery cell, and adhesively bonding the at least one crosslinkable adhesive layer of the adhesive film and at least one top side of the battery cell, wherein the methods further comprise at least partly crosslinking the crosslinkable adhesive layer.