Electrochemical Cell Insulation Coating for Welded Edge Coverage
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Solution Overview
Problem
Current methods for electrical insulation of electrochemical cells in vehicles are complex, time-consuming, and prone to failure due to the use of external insulating films that can be scratched or detached, leading to safety and reliability issues.
Innovation Solution
A method for depositing an electrical insulation layer on electrochemical cells that covers the upper edge and corners in a single step using ultraviolet crosslinking, avoiding the need for multiple insulation steps and thermal curing, with a masking device ensuring precise coverage of terminals and efficient adhesion.
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 damaging the electrochemical cell, but the film is easily scratched or damaged by external substances and may detach over time
Solution Approach 1:
The patent replaces the mechanical bonding system (adhesive bonding of PET film) with a chemical deposition system (photocuring of polymer resin). The insulating layer is formed by depositing a polymer-forming resin that is then photocured to create a durable, integrated coating that becomes part of the housing structure rather than a separate bonded layer.
Solution Approach 2:
The patent uses a composite approach by combining the polymer-forming resin with specific properties (electrical insulation, adhesion, durability) to create an insulating layer that integrates multiple functions. The resin formulation and photocuring process create a composite structure that combines the benefits of chemical bonding with mechanical durability.
2Strength
If insulating material is deposited by thermal curing after welding the cover to the housing, then durable electrical insulation is achieved, but the temperature rise damages the electrochemical cell
Solution Approach 1:
The patent replaces the thermal curing system with a photocuring system. Instead of using heat to cure the polymer resin, ultraviolet (UV) light is used to initiate the polymerization reaction. This substitution allows the insulating layer to be cured at ambient temperature, eliminating the temperature-related damage to the electrochemical cell while maintaining the durability benefits of cured polymer insulation.
Solution Approach 2:
The patent changes the curing parameter from temperature (thermal curing) to light wavelength (photocuring). By using UV light instead of heat as the curing energy source, the process parameters are fundamentally changed to operate at ambient temperature conditions, thereby protecting the temperature-sensitive electrochemical cell while achieving complete polymerization and durable insulation.
3Reliability
If multiple insulation steps are performed including masking and subsequent deposition operations, then complete electrical insulation coverage is achieved, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The patent merges the insulation deposition operation with the welding operation by performing the photocuring deposition after welding but in a single continuous process step. The polymer-forming resin is applied and photocured in one operation that covers all required surfaces (housing, cover, and welded zones) simultaneously, eliminating the need for separate masking and multiple deposition steps required by traditional methods.
Solution Approach 2:
The patent performs preliminary welding of the cover to the housing before applying and photocuring the insulating resin layer. This sequencing allows the resin to be deposited over the entire assembly including welded zones in a single subsequent operation, rather than requiring multiple insulation steps. The preliminary welding creates a stable base structure that can be uniformly coated and cured in one final insulation step.
4Reliability
If the insulating film is applied before welding the cover to the housing, then the film may be damaged by the welding process or fail to provide insulation at the welded zones
Solution Approach 1:
The patent performs welding as a preliminary action before applying the insulating resin layer. By completing the welding operation first, the structural assembly is finalized and then the insulation is applied in a single subsequent photocuring step that covers all surfaces including welded zones. This sequencing ensures the insulation is applied to the final configuration without risk of damage during welding.
Solution Approach 2:
The patent replaces the traditional sequence of applying insulating film before welding with a photocuring deposition system applied after welding. The UV-based photocuring process allows the resin to be applied and cured in one step over the completed welded assembly, ensuring complete coverage of welded zones without the film damage issues that would occur with thermal processes or pre-welding application.
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 and accelerates the manufacturing process while providing excellent long-term electrical insulation of the upper edge and corners, preventing blisters and ensuring the safety and reliability of the electrochemical cells.
Implementation Method 1
The insulating film-forming resin may be obtained by photocuring a prepolymer
Data Source
AI summary
The invention relates to a method for depositing an electrical insulation layer on an electrochemical cell including a lower wall, a side wall and an upper wall on which a positive terminal and a negative terminal are arranged, the side wall and the upper wall being connected by a peripheral edge. The deposition method includes a step of depositing an electrical insulation layer during which the electrical insulation layer is deposited on the lower wall, the side wall, and only on one border of the upper wall the border extending from the peripheral edge toward the interior of the upper wall over a distance d, so as to form an electrical insulation strip covering the border and surrounding a central zone of the upper wall.