Direct Water-Cooling Battery Cell Case With Sacrificial Corrosion Layer
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Solution Overview
Problem
Conventional direct water-cooling battery modules face corrosion issues due to the material characteristics of the battery cell case, leading to increased manufacturing costs and uneven antirust agent application, which affects the battery's performance and lifespan.
Innovation Solution
A sacrificial metal sheet with a higher metal ionization tendency than the battery cell case is bonded to the case using a pressure welding method, creating a scratch region on the plating layer to enhance corrosion resistance and simplify the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a nickel-plated iron exterior case is used for battery cells in direct water-cooling method, then cooling efficiency is improved, but corrosion resistance deteriorates
Solution Approach 1:
The patent applies a sacrificial metal coating (zinc, aluminum, or magnesium) on the nickel-plated iron exterior case. This sacrificial layer acts as a disposable protective barrier that corrodes preferentially, sacrificing itself to protect the main battery cell case from corrosion while maintaining cooling efficiency.
Solution Approach 2:
The patent creates a composite structure by combining nickel-plated iron (for structural strength and cooling efficiency) with a sacrificial metal coating (for corrosion protection). This composite approach allows the system to simultaneously achieve both cooling efficiency and corrosion resistance through the synergistic combination of different materials.
2Reliability
If insulating oil or special cooling water is used to prevent corrosion, then corrosion resistance is improved, but manufacturing cost increases
Solution Approach 1:
The sacrificial metal coating serves as a low-cost, disposable protective layer that eliminates the need for expensive insulating oils or special cooling waters. The coating can be applied through standard electroplating or dip-coating processes, significantly reducing material costs while providing effective corrosion protection.
Solution Approach 2:
The sacrificial metal coating provides self-service corrosion protection through galvanic action, automatically protecting the battery cell case without requiring additional insulating treatments or special cooling water formulations. The system protects itself through the electrochemical properties of the sacrificial layer.
3Reliability
If antirust liquid is applied to the exterior case, then corrosion resistance is improved, but manufacturing complexity increases due to post-treatment processes
Solution Approach 1:
The sacrificial metal coating is applied as a preliminary protective layer during the standard plating process, before the battery cell assembly. This preliminary protection eliminates the need for subsequent post-treatment processes such as non-woven fabric covering, simplifying the manufacturing workflow.
Solution Approach 2:
The sacrificial coating provides self-service corrosion protection through its electrochemical properties, eliminating the need for additional maintenance or post-treatment processes. The coating automatically protects the case through galvanic action without requiring external intervention.
4Reliability
If antirust liquid is applied to the exterior case, then corrosion resistance is improved, but application uniformity deteriorates due to surface tension causing flow down
Solution Approach 1:
The sacrificial metal coating is applied as a durable, uniform layer through established plating or dip-coating techniques, replacing the problematic antirust liquid application. The coating adheres uniformly to the case surface without flowing down, ensuring consistent corrosion protection.
Solution Approach 2:
The combination of nickel-plated iron with sacrificial metal coating creates a composite structure where the sacrificial layer provides uniform corrosion protection. The metallurgical bonding ensures even distribution without the surface tension issues that plague liquid antirust applications.
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 solution improves the corrosion resistance of the battery cell by promoting stable electrical connections and reducing manufacturing defects, while using general cooling water without the need for insulating treatments, thus lowering costs and ensuring even antirust agent application.
Implementation Method 1
a sacrificial metal sheet having a higher metal ionization tendency than that of a battery cell case
Implementation Method 2
bonding a sacrificial metal sheet to one side of the unit plate material to cover the scratch region
Data Source
AI summary
A battery cell manufacturing method comprises scratching a partial region of a plating layer of unit plate material to form a scratch region on the unit plate material; bonding a sacrificial metal sheet to one side of the unit plate material to cover the scratch region; and processing the unit plate material into a cylindrical shape so that the sacrificial metal sheet is exposed to the outside. A battery cell and battery module according to the same are also provided.