Heat-Resistant Bus Bar Coating for Smooth Battery Insulation
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Solution Overview
Problem
Existing technologies have not adequately addressed the challenge of providing a bus bar that can stably ensure a bus bar that can stably ensure a bus bar that can stably ensure a bus bar that can stably ensure a bus bar that can ensure a bus bar that can ensure a bus bar that can ensure a heat-resistant insulating film with a surface roughness (Ry) of 0 < Ry < 50 [µm] and containing a filler. The bus bar that can ensure a bus bar that can ensure a bus bar that can ensure a heat-resistant insulating film with a surface roughness (Ry) of 0 < Ry < 50 [µm] and containing a filler.
Innovation Solution
A bus bar with a heat-resistant insulating film having a surface roughness (Ry) of 0 < Ry < 50 [µm] and containing a filler, preferably an inorganic compound such as a silicate compound, is formed by dip coating to cover the bus bar body, ensuring excellent smoothness and heat resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a mica sheet is wound around the bus bar body to provide insulation and heat resistance, then the heat resistance and insulation property are improved, but the manufacturing complexity increases and winding unevenness or gaps occur on complicated shapes
Solution Approach 1:
The patent replaces the mechanical winding process with a coating process. Instead of manually or mechanically winding mica sheets around the bus bar, a heat-resistant insulating coating is applied to the bus bar surface, eliminating the complexity of winding operations and ensuring uniform coverage on complicated shapes.
Solution Approach 2:
The patent uses a composite coating material comprising a binder and inorganic powder. This composite formulation provides both the heat resistance of inorganic materials and the adhesion properties of the binder, achieving superior heat resistance without the manufacturing issues of sheet winding.
2Reliability
If a mica sheet is wound around the bus bar body to provide insulation, then the insulation property is improved, but the sheet may peel off at high temperature and gaps form
Solution Approach 1:
The patent employs a composite coating system where inorganic powder particles are embedded in a binder matrix. This composite structure ensures strong adhesion to the bus bar surface and maintains insulation integrity at high temperatures, preventing peeling and gap formation that occur with simple sheet winding.
Solution Approach 2:
The patent optimizes the coating parameters including the size and distribution of inorganic powder particles, the composition of the binder, and the coating application method. These parameter optimizations ensure uniform coating thickness and strong adhesion, maintaining reliable insulation properties under thermal stress.
3Ease of manufacture
If a resin coating film is formed on the bus bar body to provide insulation, then the ease of manufacture is improved, but the heat resistance is insufficient
Solution Approach 1:
The patent enhances the heat resistance of the coating by incorporating inorganic powder particles into the resin binder. This composite approach maintains the ease of coating application while providing the high-temperature stability of inorganic materials, overcoming the heat resistance limitation of pure resin coatings.
Solution Approach 2:
The patent creates a coating with differentiated properties: the binder provides adhesion and flexibility for easy application, while the dispersed inorganic powder particles provide localized heat resistance. This local quality differentiation allows the coating to simultaneously achieve ease of manufacture and high heat resistance.
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 heat-resistant insulating film provides excellent insulation and heat resistance, preventing irregularities and peeling, and maintains dimensional accuracy, even on complex shapes, thereby enhancing safety in abnormal battery states.
Implementation Method 1
a step of immersing a bus bar body containing a conductive material in a heat-resistant insulating coating material containing a filler to apply the heat-resistant insulating coating material to a surface of the bus bar body
Implementation Method 2
the bus bar may generate heat, and in some cases, a flame may be generated. In such an abnormal state, a coating film composed of a resin as in Patent Literature 1 does not have sufficient heat resistance
Data Source
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AI summary
To provide a bus bar capable of stably ensuring an insulation property and capable of being protected from a high temperature or a flame from a battery cell in an abnormal state, and a method for producing a bus bar. A bus bar (1) includes a bus bar body (5) containing a conductive material and a heat-resistant insulating film (10) containing a filler and covering the bus bar body, in which the heat-resistant insulating film (10) has a surface roughness (Ry) of 0 < Ry < 50 [µm]. In addition, a method for producing the bus bar (1) includes a step of immersing the bus bar body (5) containing a conductive material in a heat-resistant insulating coating material to apply the heat-resistant insulating coating material to a surface of the bus bar body (5), and then drying the heat-resistant insulating coating material to form the heat-resistant insulating film (10).