Battery Pack Cell Module Silicone Coating Against Moisture and Carbonization
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Solution Overview
Problem
Battery packs face issues such as carbonization and reduced service life due to exposure to harsh environments, leading to safety concerns like fire and explosion.
Innovation Solution
A silicone immersion coating is applied to the cell module, including the cell holder, circuit board, and connectors, providing insulation, moisture-proofing, and corrosion resistance, formed by immersing the components in a silicone protective liquid for less than 2 minutes, with specific substance proportions and thicknesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If the battery pack is used in harsh environments without protection, then the service life is reduced, but adding protective measures increases device complexity
Solution Approach 1:
The patent applies a silicone coating layer (5-50 μm thick) over the cell pole pieces and cell ends, forming a flexible protective film that prevents carbonization and corrosion without adding mechanical structural complexity. This thin film approach extends service life in harsh environments while maintaining simplicity in the battery pack design.
Solution Approach 2:
The patent modifies the chemical surface properties of the cell components by applying a silicone coating, changing the surface composition from vulnerable metal surfaces to chemically resistant silicone surfaces. This parameter change (surface chemistry) provides protection against carbonization and corrosion, extending service life without altering the mechanical structure or increasing device complexity.
2Ease of manufacture
If no protective coating is applied to the cell module, then the manufacturing process is simple, but carbonization occurs on cell pole pieces and ends reducing safety
Solution Approach 1:
The silicone coating layer (5-50 μm) is applied as a thin flexible film over the cell pole pieces and ends, preventing carbonization and improving safety. The coating process integrates into existing manufacturing workflows, maintaining ease of manufacture while significantly improving reliability by preventing hazardous carbonization.
Solution Approach 2:
The silicone coating represents a low-cost, simple protective layer that can be applied through straightforward immersion or spraying processes. This inexpensive coating provides essential safety protection against carbonization without requiring complex manufacturing equipment or processes, maintaining ease of manufacture while improving safety.
3Reliability
If a thick protective coating is applied to the cell module, then protection against moisture and corrosion is improved, but the battery pack volume increases
Solution Approach 1:
The patent employs a thin silicone coating layer (5-50 μm) that provides effective moisture and corrosion protection without requiring thick protective layers. This thin film approach delivers reliable protection against environmental degradation while minimizing volume increase, maintaining a compact battery pack design.
Solution Approach 2:
The patent changes the surface properties of cell components through silicone coating, creating a chemically resistant barrier that prevents moisture ingress and corrosion. This surface modification provides robust protection against environmental factors while adding minimal volume, as the protection is achieved at the molecular surface level rather than through thick structural layers.
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
Enhances safety and durability by preventing short circuits, moisture ingress, and corrosion, reducing the risk of fire and explosion, thus extending the battery pack's service life.
Implementation Method 1
providing insulation, moisture-proofing, and corrosion resistance
Implementation Method 2
providing insulation, moisture-proofing, and corrosion resistance
Implementation Method 3
the silicone immersion coating is applied to at least the cell module... formed by immersing the components in a silicone protective liquid
Data Source
AI summary
A power tool includes a tool body, an electric motor disposed in the tool body, and a battery interface configured to be connected to a battery pack for supplying power to the electric motor. The battery pack includes a housing; and a cell module disposed in the housing. The cell module includes multiple cells; a cell holder configured to support the multiple cells; and a circuit board electrically connected to at least the multiple cells. The battery pack further includes a terminal assembly electrically connected to at least the circuit board or the multiple cells and connecting the cell module to the battery interface for electric power transmission; and a silicone immersion coating applied to at least the cell module.