Battery Cell Insulation Coating for Edge Coverage and Adhesion
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Solution Overview
Problem
Existing methods for electrical insulation of electrochemical cells in battery packs are complex, time-consuming, and prone to failure due to the use of external insulating films that can be scratched or detached, compromising safety and reliability.
Innovation Solution
A method for depositing an electrical insulation layer on electrochemical cells that involves a single step of ultraviolet crosslinking, covering the lower wall, side wall, and upper wall border, with a masking device ensuring the terminals are not insulated, simplifying the process and providing robust adhesion without thermal damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a polyethylene terephthalate (PET) insulating film is bonded onto the housing surface after welding, then electrical insulation is achieved at ambient temperature without thermal damage, but the film is easily scratched or detached during production or operation
Solution Approach 1:
The patent merges the insulating film application with the welding process by depositing the film directly on the housing surface before welding the cover. This integration ensures the film is firmly attached to the housing structure, preventing detachment while maintaining electrical insulation properties.
Solution Approach 2:
The insulating film is deposited on the housing surface before the welding operation. This preliminary action allows the film to be in place during welding, ensuring it is properly positioned and adhered before any subsequent handling or operation that might cause scratching or detachment.
2Reliability
If multiple insulation steps are performed including masking with adhesive strips, then complete insulation coverage is achieved, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The patent extracts and eliminates the masking step from the traditional multi-step insulation process. By depositing the insulating film directly on the housing surface before welding, the need for adhesive strips and masking is removed, significantly simplifying the manufacturing process while maintaining complete insulation coverage.
Solution Approach 2:
The patent combines the insulating film deposition with the welding preparation process. The film is applied to the housing surface as part of the pre-welding operations, integrating two functions into one streamlined process that improves manufacturing efficiency without compromising insulation reliability.
3Ease of manufacture
If the insulating film is applied after welding the cover to the housing, then the welding operation is not interfered with, but subsequent handling may scratch or damage the film
Solution Approach 1:
The insulating film is deposited on the housing surface before the welding operation. This preliminary action ensures the film is already in place and protected during welding, eliminating the risk of damage during subsequent handling while not interfering with the welding process itself.
Solution Approach 2:
The patent provides beforehand protection by applying the insulating film to the housing surface prior to welding. This creates a protective layer that cushions the housing surface during subsequent operations, preventing scratches or damage that would occur if the film were applied afterward.
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
This method simplifies the manufacturing process, ensures excellent insulation of the upper edge and corners, and maintains insulation integrity over time without blistering or detachment, enhancing the safety and reliability of electrochemical cells.
Implementation Method 1
The layer is then hardened by means of an ultraviolet crosslinking method
Data Source
Figure 1
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Figure 4~5
AI summary
The invention relates to a method for depositing an electrical insulation layer (1) on an electrochemical cell (2) comprising a lower wall, a side wall (4) and an upper wall (5) on which a positive terminal (6) and a negative terminal (7) are arranged, the side wall (4) and the upper wall (5) being connected by a peripheral edge (8). The deposition method comprises a step of depositing an electrical insulation layer (1) during which the electrical insulation layer (1) is deposited on the lower wall, the side wall (4), and only on one border (9) of the upper wall (5), the border (9) extending from the peripheral edge (8) toward the interior of the upper wall (5) over a distance d, so as to form an electrical insulation strip (14) covering the border and surrounding a central zone (10) of the upper wall.