Polyurethane Elastomer Insulation for Battery Pack Component Separation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electrical insulation materials used in battery packs are prone to damage and penetration by sharp or abrasive components, leading to potential short circuits and hazardous conditions due to their lack of durability.
Innovation Solution
The use of polyurethane elastomer-based materials, such as tapes, for electrical separation between components in battery packs, which provides enhanced resistance to puncture and penetration, ensuring reliable electrical insulation throughout the system's life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electrical insulation materials (kapton, nomex, fishpaper) are used for component separation, then electrical insulation function is achieved, but the materials are easily damaged and penetrated by sharp or abrasive surfaces during normal use
Solution Approach 1:
The patent changes the material parameter from conventional insulating materials (kapton, nomex, fishpaper) to polyurethane elastomer-based material, which has superior mechanical properties including resistance to puncture, cut, and penetration while maintaining electrical insulation capabilities
Solution Approach 2:
The patent employs a composite insulation structure consisting of multiple layers: a first insulating layer, a polyurethane elastomer-based material layer, and a second insulating layer. This composite structure combines the electrical insulation properties of traditional materials with the enhanced mechanical protection of polyurethane elastomer
2Duration of action of stationary object
If conventional insulating materials are used, then initial electrical insulation is provided, but the materials cannot withstand forces applied by unsmooth areas of components during system life
Solution Approach 1:
The patent changes the material parameter from conventional insulating materials to polyurethane elastomer-based material, which has superior mechanical properties including resistance to puncture, cut, and penetration while maintaining electrical insulation capabilities
Solution Approach 2:
The patent applies a polyurethane elastomer-based material layer between the insulating materials and sharp or abrasive surfaces, providing beforehand protection against forces and damage that would otherwise compromise the insulation during system operation
Data Source
AI summary
An electrical insulation system and method for electrical power storage component separation is disclosed. Some implementations of the system use various forms of polyurethane elastomer based material such as tapes to electrically separate various components of electrical power storage devices such as battery packs. These components can include cells, connecting tabs, printed circuit assemblies, solder joints, nickel strips, and other conductive members.