Moisture-Resistant Coating for Lithium-Ion Battery Safety
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Solution Overview
Problem
Lithium ion batteries are prone to thermal runaway, leading to uncontrolled heating, swelling, and potential fires or explosions due to moisture and corrosive agent exposure, which existing technologies fail to adequately address.
Innovation Solution
Applying a moisture-resistant coating to energy storage devices, including lithium ion batteries, to prevent moisture and corrosive agent exposure, thereby protecting internal components and preventing electrolyte leakage and electrical arcs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If lithium ion batteries are used for energy storage, then high energy density and light weight are achieved, but the batteries become susceptible to thermal runaway and moisture damage
Solution Approach 1:
A moisture-resistant coating is applied as an intermediary layer between the battery components and the external environment. This coating acts as a protective barrier that prevents moisture and corrosive agents from reaching sensitive internal components, thereby resolving the contradiction between maintaining high energy density and improving reliability against environmental damage.
Solution Approach 2:
The moisture-resistant coating serves as a sacrificial protective layer that can be applied relatively simply to provide long-term protection. While the coating itself may have limited functional life, it continuously protects the high-value battery components, allowing the battery to maintain its high energy density characteristics while gaining enhanced reliability.
2Temperature
If separator melts during thermal runaway, then pressure increases causing cell swelling, but electrolyte leakage and electrical arcs may occur leading to fire or explosion
Solution Approach 1:
The moisture-resistant coating is applied beforehand to create a protective cushion or barrier around the battery components. When thermal runaway occurs and the separator melts, this pre-applied coating helps contain the harmful effects, preventing electrolyte leakage and reducing the risk of electrical arcs, thereby addressing the contradiction between temperature control and preventing harmful effects.
3Reliability
If moisture-resistant coating is applied to battery components, then protection against moisture and corrosive agents is improved, but device complexity increases
Solution Approach 1:
The moisture-resistant coating is implemented as a thin film that can be applied conformally to complex battery component geometries. This approach provides comprehensive protection against moisture and corrosive agents while minimizing the added complexity, as the thin film nature allows for simpler application processes compared to thicker or more rigid protective structures.
Data Source
AI summary
The disclosure extends to protectively coated energy storage devices, such as rechargeable batteries, and associated methods of forming the same. An energy storage device, such as a rechargeable battery, may comprise a cell including at least one electrical terminal and a circuit board electrically coupled to the at least one electrical terminal. The rechargeable battery may also include a protective coating on at least a portion of at least one of a surface of the cell and/or at least one surface of the circuit board. The protective coating may reside between the circuit board and the cell. The protective coating may comprise a moisture resistant coating that will withstand exposure to corrosive agents, including electrolytes, corrosive gases and dust.