Battery Casing Film Coating With Welded Overlap Seams
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Solution Overview
Problem
Existing battery casings, often made of metal for structural strength, are electrically conductive and require insulation to prevent corrosion and ensure reliable operation, but existing methods like gluing may not provide a secure seal, especially at seams where liquids can penetrate.
Innovation Solution
A battery design featuring a casing completely surrounded by an electrically insulating coating made of film material with overlapping seams that are welded using a hot welding tool, ensuring a fluid-tight seal and preventing corrosion by melting and solidifying the film material at the seams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal casing is used for structural strength, then the structural load capacity is improved, but the electrical conductivity increases causing corrosion risk
Solution Approach 1:
The patent applies a film coating made of flexible, electrically insulating material (such as aluminum foil or plastic film) over the metal casing. This thin film layer provides electrical insulation to prevent corrosion while maintaining the structural integrity of the metal casing underneath.
Solution Approach 2:
The battery packaging combines metal casing material with film coating material to create a composite structure. The metal provides structural strength while the film layer provides electrical insulation and corrosion protection, achieving both requirements simultaneously.
2Object-affected harmful factors
If an electrically insulating coating is applied to the casing, then the corrosion protection is improved, but the sealing reliability at seams deteriorates
Solution Approach 1:
The film material is designed with overlapping edges that extend beyond the casing seams before sealing. This preliminary extension ensures that the sealing process can create a reliable seal that covers the entire seam area, preventing liquid penetration while maintaining electrical insulation.
Solution Approach 2:
The sealing process utilizes thermal energy to temporarily soften or melt the film material at the overlapping seams, allowing the layers to bond together. This phase transition enables creation of a secure, fluid-tight seal that maintains both electrical insulation and structural integrity.
3Object-affected harmful factors
If a film coating is used instead of a metal casing, then the electrical insulation is improved, but the structural load capacity deteriorates
Solution Approach 1:
The patent merges the advantages of both metal casings and film coatings by combining them into a single hybrid structure. The metal casing provides the structural load-bearing framework while the film coating layer provides electrical insulation, achieving both requirements that neither material could satisfy alone.
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 provides a secure, cost-effective, and reliable sealing of the battery casing seams, preventing liquid penetration and ensuring the structural integrity and operational reliability of the battery.
Implementation Method 1
welded using a hot welding tool, ensuring a fluid-tight seal and preventing corrosion by melting and solidifying the film material at the seams
Data Source
AI summary
A battery comprises a battery element or multiple battery elements accommodated in a casing and an electrically insulating coating for the casing. The coating is formed of at least one film material. The at least one film material overlaps on at least one seam of the coating. The at least one overlapping film material is welded on at least one seam in order to achieve the best possible sealing coating.