Battery Terminal Sealing with Solventless Light-Curable Acid Barriers
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Solution Overview
Problem
Conventional battery terminals face issues with thermal expansion mismatch and solvent-based sealants, leading to electrolyte leakage and gas ingress, while existing alternatives like D-limonene are flammable and have limited commercial applicability due to slow evaporation.
Innovation Solution
The use of a non-toxic, light-curable resin as a solventless sealant applied to battery parts, which forms a labyrinthine path to prevent fluid migration and is cured without hazardous solvents, ensuring a secure interface between battery terminals and containers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional solvent-based sealants (e.g., polyisobutylene dissolved in TCE) are used to seal the interface between battery terminals and container, then sealing effectiveness is improved, but toxicity and flammability increase due to hazardous solvents
Solution Approach 1:
The invention changes the physical state and composition parameters of the sealant by using a solventless paste formulation instead of a solvent-based solution. This eliminates the need for hazardous solvents like TCE while maintaining effective sealing properties through the paste's viscous consistency and active sealing components.
Solution Approach 2:
The invention extracts and removes the hazardous solvent component from the sealant system entirely. By using a solventless paste formulation, the harmful solvent is completely eliminated while the sealing function is maintained through alternative mechanisms in the paste composition.
2Object-affected harmful factors
If D-limonene is used as a substitute solvent for TCE, then toxicity is reduced, but flammability remains and evaporation speed is slow limiting commercial applicability
Solution Approach 1:
The invention completely removes the solvent component from the system by using a solventless paste formulation. This eliminates both the toxicity issues associated with traditional solvents and the productivity limitations caused by slow evaporation rates of alternatives like D-limonene.
Solution Approach 2:
The invention replaces the chemical evaporation mechanism with a mechanical/curing mechanism. Instead of relying on solvent evaporation to leave behind a sealing film, the paste formulation cures or sets through alternative mechanisms that do not require volatile solvent removal, thereby eliminating evaporation time constraints.
3Reliability
If thermal cycling occurs between battery container and lead terminals with different coefficients of thermal expansion, then sealing reliability deteriorates due to interface separation, but no effective countermeasure is provided
Solution Approach 1:
The invention changes the mechanical properties parameters of the sealant paste to create a more compliant material that can accommodate thermal expansion differences. The paste formulation includes components that provide elasticity and flexibility, allowing the seal to maintain integrity during thermal cycling without rigid bonding that would fail under differential expansion.
Solution Approach 2:
The invention provides beforehand cushioning by using a compliant paste formulation that anticipates and accommodates thermal expansion differences. The paste acts as a buffer that absorbs the stresses generated during thermal cycling, preventing interface separation and maintaining sealing reliability before problems occur.
4Strength
If battery terminals are subjected to repeated twisting or torsional loads, then mechanical connection strength deteriorates causing terminals to become loose, but sealing effectiveness is compromised
Solution Approach 1:
The invention changes the mechanical property parameters of the interface by using a compliant paste formulation that provides both mechanical flexibility and sealing continuity. The paste accommodates torsional movements without cracking or failing, maintaining both mechanical connection integrity and sealing effectiveness under dynamic loading conditions.
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 solution effectively seals the interface between battery parts and containers, preventing electrolyte leakage and gas ingress, while being non-toxic and environmentally friendly, reducing manufacturing complexity and costs.
Implementation Method 1
a light-curable material applied to at least a portion of an exterior surface of the base portion
Data Source
AI summary
Battery parts, such as battery terminals, and associated systems and methods for making the same are disclosed herein. In some embodiments, a battery part includes a body having a base portion and a lug portion extending from the base portion. The battery part can further include a light-curable sealing material at least partially covering an exterior surface of the base portion. The sealing material is configured to seal an interface between the battery part and the material of a battery container when the base portion is embedded in the battery container material.