UV-Cured Insulating Coating for Battery Cell Shear Strength
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Solution Overview
Problem
Existing methods for wrapping battery cells with external protective films, such as PET or PP films, suffer from issues like air bubbles, wrinkles, peeling, and inadequate shear strength, leading to high defect rates, increased costs, and safety concerns.
Innovation Solution
A method involving spraying an insulating paint onto the battery cell surface and curing it with UV light at varying power densities to form a coating, which enhances adhesion and disperses stress concentration, resulting in a high shear strength and improved insulating properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If external protective films (PET or PP films) are wrapped around battery cells, then insulating property is improved, but manufacturing precision deteriorates due to air bubbles, wrinkles, and peeling
Solution Approach 1:
The patent replaces the mechanical wrapping process with a coating process. Instead of mechanically wrapping external protective films around battery cells, an insulating coating is applied directly to the battery cell surface through spraying or dipping, eliminating the mechanical operations that cause air bubbles, wrinkles, and peeling while maintaining insulating properties.
Solution Approach 2:
The patent uses composite material structure consisting of the battery cell surface combined with an insulating coating layer. This composite structure integrates the insulating function directly into the battery cell surface, replacing the separate external protective film wrapping and achieving better adhesion without wrinkles or peeling.
2Reliability
If external protective films are wrapped around battery cells, then insulating property is improved, but strength deteriorates due to inadequate shear strength
Solution Approach 1:
The patent creates a composite structure where the insulating coating becomes an integral part of the battery cell surface. This composite material approach achieves superior adhesion strength and shear resistance compared to externally wrapped films, as the coating is chemically and physically bonded to the surface rather than mechanically attached.
Solution Approach 2:
The patent replaces the mechanical attachment of external films with a chemical bonding process. The insulating coating is applied and cured to form a strong bond with the battery cell surface, achieving adequate shear strength that exceeds the mechanical wrapping method.
3Reliability
If external protective films are used, then insulating property is improved, but loss of substance increases due to material wastage
Solution Approach 1:
The patent replaces the wrapping process with a coating process that applies insulating material directly to the battery cell surface. This method reduces material wastage from defective wrapped films that must be discarded, as the coating can be applied more precisely and uniformly without creating defects that lead to material rejection.
Solution Approach 2:
The patent eliminates the need to discard defective external protective films by using a coating method that produces fewer defects. The insulating coating process allows for better control and recovery of material, reducing the rate at which material must be discarded due to air bubbles, wrinkles, or peeling issues.
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 insulating coating achieves superior adhesion, reduces material wastage, and ensures robust structural stability with a shear strength of over 10 MPa, enhancing voltage endurance and insulating properties while reducing production costs.
Implementation Method 1
irradiating the semi-finished product under ultraviolet light with a power density of P1 for T1 seconds, followed by irradiating the semi-finished product under ultraviolet light with a power density of P2 for T2 seconds
Data Source
AI summary
The present disclosure provides a battery cell with a surface containing an insulating coating, a method for preparing the same, and a battery pack including the same. The method for preparing the battery cell includes: S1. spraying an insulating paint onto a spraying surface of a battery cell to obtain a semi-finished product; S2. irradiating the semi-finished product under ultraviolet light with a power density of P1 for T1 seconds, followed by irradiating the semi-finished product under ultraviolet light with a power density of P2 for T2 seconds, to obtain the battery cell with the surface containing the insulating coating; wherein 0.1 W/cm2≤P1≤2.5 W/cm2, 0<T1≤2, 0.2 W/cm2≤P2≤3.5 W/cm2, and 1≤T2≤8.