Silicone-Coated Battery Top Insulator for Clean Punching
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Solution Overview
Problem
Existing top insulators for secondary batteries face challenges with heat resistance, chemical resistance, and dust generation during punching, leading to reduced battery performance and increased manufacturing costs.
Innovation Solution
A top insulator is manufactured by applying silicone rubber to a glass fiber fabric, which is then punched to create a disc shape. This process enhances heat resistance, chemical resistance, and reduces dust generation during production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a thermoplastic resin is used for the top insulator, then punching processability is excellent, but heat resistance is insufficient (melting point 200-250°C)
Solution Approach 1:
The patent uses a composite structure consisting of a glass fiber fabric base layer combined with a thermosetting resin coating layer. The glass fiber fabric provides structural integrity and punching processability, while the thermosetting resin coating (epoxy, phenolic, or polyester resin) provides enhanced heat resistance and chemical resistance. This composite approach resolves the contradiction by combining materials with complementary properties.
2Temperature
If the thickness of the top insulator is increased to improve heat resistance, then heat resistance is improved, but battery capacity is reduced due to decreased internal space
Solution Approach 1:
The patent changes the material parameters of the top insulator by using thermosetting resins with higher glass transition temperatures and melting points compared to thermoplastic resins. This allows the insulator to maintain adequate heat resistance at a reduced thickness, thereby preserving battery internal space and capacity while meeting thermal requirements.
3Temperature
If glass fiber fabric is coated with phenol and punched, then heat resistance is improved, but dust generation is excessive
Solution Approach 1:
The patent modifies the resin coating parameters by using epoxy, phenolic, or polyester resins with optimized formulation and curing conditions. These parameter changes reduce dust generation during punching compared to phenol coating, while maintaining adequate heat resistance. The specific resin selection and coating thickness are optimized to minimize harmful dust generation.
4Adaptability or versatility
If a flexible polymer material is used for the pouch case, then adaptability is improved, but structural strength is reduced compared to metal or plastic cases
Solution Approach 1:
The patent uses a composite pouch case structure combining flexible polymer layers with reinforcement layers (such as aluminum foil or mesh). This composite structure maintains the shape adaptability and flexibility of the polymer material while adding structural strength through the reinforcement layers, resolving the contradiction between adaptability and strength.
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 silicone-coated glass fiber top insulator exhibits improved heat resistance up to 250°C, maintains chemical stability in lithium-based electrolytes, and suppresses dust generation during punching, enabling continuous production and reducing manufacturing costs.
Implementation Method 1
The silicone-coated glass fiber top insulator exhibits improved heat resistance up to 250°C
Implementation Method 2
maintains chemical stability in lithium-based electrolytes
Data Source
AI summary
To solve the above problem, a method for manufacturing a top insulator configured to be inserted into a case of a secondary battery, according to an embodiment of the present invention includes: preparing a top insulator fabric by applying a silicone rubber to at least one surface of a glass fiber fabric formed by crossing weft yarns and warp yarns of glass fiber raw yarns; and punching the top insulator fabric.