Battery Protection Layer UV Curing Insulation
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Solution Overview
Problem
Soft package secondary batteries face issues with electrical corrosion and short circuits due to inadequate insulation, leading to reduced service life and low production efficiency, particularly with conventional insulation tapes having limited adhesive force and reliability.
Innovation Solution
A battery design incorporating a protection layer formed from insulation curing materials like ultraviolet curing adhesives, silica gel, epoxy resin, or hot-melt resin, which is tightly adhered to the circuit board assembly and terminal, providing comprehensive insulation protection and adaptability to various structures, thereby enhancing reliability and production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulation tape is adhered on the surface of the circuit board assembly, then insulation protection is provided, but the adhesive force is limited and reliability is low
Solution Approach 1:
The patent replaces the mechanical adhesive bonding system (insulation tape with adhesive) with a chemical curing system (ultraviolet curing adhesive). The ultraviolet curing adhesive undergoes photochemical polymerization when exposed to UV light, transforming from a liquid state to a solid gel state, creating a much stronger chemical bond between the circuit board assembly and the protective layer. This substitution of mechanical bonding with chemical bonding significantly improves adhesion strength and insulation reliability.
Solution Approach 2:
The patent changes the physical and chemical parameters of the adhesive material by using ultraviolet curing technology. The adhesive's state is transformed from liquid to solid through UV irradiation, and its bonding mechanism changes from physical adhesion to chemical bonding. This parameter change enables the adhesive to achieve both high reliability (through strong chemical bonds) and high production efficiency (through rapid curing without complex heating or pressing processes).
2Reliability
If the insulation tape is cut according to a particular structure, then insulation coverage is achieved, but production efficiency is reduced
Solution Approach 1:
The patent applies ultraviolet curing adhesive that can adapt to various structural configurations of circuit board assemblies. The adhesive can be applied as a coating that conforms to different shapes, sizes, and layouts of electronic components, eliminating the need for pre-cutting insulation tape to specific patterns. This universal applicability maintains complete insulation coverage while significantly improving production efficiency by removing the time-consuming cutting and fitting process.
Solution Approach 2:
The ultraviolet curing adhesive has the self-service capability of automatically adapting to the circuit board assembly's structure through its liquid state during application, then self-setting into a solid protective layer upon UV exposure. This self-adaptation and self-fixing property eliminates the need for manual cutting and precise positioning, allowing the insulation material to automatically conform to any circuit board layout while maintaining complete coverage.
3Reliability
If a protection layer is formed by ultraviolet curing adhesive, then insulation performance and reliability are improved, but the manufacturing process requires UV curing equipment
Solution Approach 1:
The patent replaces traditional thermal curing equipment or complex bonding systems with ultraviolet curing technology. The UV curing process uses electromagnetic radiation instead of thermal energy, allowing for rapid curing at room temperature without complex heating systems. This substitution reduces manufacturing equipment complexity while achieving superior insulation performance through strong chemical bonding.
Solution Approach 2:
The patent utilizes the phase transition of the ultraviolet curing adhesive from liquid to solid gel state upon UV irradiation. This phase transition occurs rapidly and completely, creating a strong, reliable protective layer. The simplicity of this phase-change mechanism eliminates the need for complex multi-stage curing equipment, requiring only UV light sources to achieve high insulation performance.
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 effectively prevents electrical corrosion and short circuits, improves the battery's service life, and increases energy density by ensuring reliable insulation across the battery's components, while also simplifying the manufacturing process with higher adaptability and efficiency.
Implementation Method 1
the protection layer is formed by an insulation curing material. Preferably, the insulation curing material is one or more of an ultraviolet curing adhesive, silica gel, an epoxy resin, a hot-melt resin, and a Nano material.
Data Source
AI summary
The present application relates to the field of batteries, and discloses a battery and a manufacturing method for the same. The battery comprises a package bag, an electrode, and a circuit board assembly. The electrode is located in the package bag, and the electrode is further provided with a terminal. The terminal has one end connected to the electrode and located inside the package bag, and the other end located outside the package bag. The other end of the terminal is electrically connected to the circuit board assembly to form a protection portion, and the protection portion is covered by a protection layer. In the foregoing embodiment, the protection layer can cover structures requiring insulation protection, such as the circuit board assembly and the terminal, and the protection layer can be tightly adhered to the surfaces of the structures, thereby improving the reliability. Moreover, the protection layer can adapt to structures of various sizes during coating, and achieves high adaptability and production efficiency.