UV-Curable Dielectric Coating for Battery Insulation
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Solution Overview
Problem
Current methods for electrically insulating battery pack components, such as PET film coatings, face challenges with high temperature compatibility, adhesion issues, and thermal impedance, particularly in electric vehicle battery packs, leading to potential thermal runaway and manufacturing inefficiencies.
Innovation Solution
A UV-curable dielectric coating comprising acrylate monomers, a photoinitiator, a urethane prepolymer, a crosslinker, adhesion promoters, and optional fillers and additives, which forms a robust, adhesive, and environmentally resistant dielectric layer upon exposure to UV radiation, providing improved adhesion and thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If powder coating is used for dielectric insulation, then electrical insulation is achieved, but high temperatures and long cure times are required which are incompatible with battery components
Solution Approach 1:
The patent changes the curing mechanism from thermal (powder coating) to photopolymerization (UV curing). The coating composition includes photoinitiators that activate upon UV exposure, enabling cure at ambient temperatures rather than requiring high temperature ovens. This parameter change in the curing process allows battery components to be insulated without thermal damage.
Solution Approach 2:
The patent replaces the thermal field (heat-based powder coating) with a photonic field (UV light-based curing). Instead of using thermal energy to initiate and complete the curing process, the invention uses UV radiation to trigger photopolymerization, substituting a mechanical/thermal system with an optical system that is compatible with heat-sensitive battery components.
2Reliability
If PET film with pressure sensitive adhesive is used, then dielectric insulation is achieved, but manufacturing complexity increases due to semi-manual installation and poor adhesion
Solution Approach 1:
The patent replaces the mechanical application process (semi-manual installation of PET film) with an automated coating and curing process. The liquid coating can be applied using standard spray or dip coating equipment, followed by UV curing in a conveyor system, enabling fully automated manufacturing without manual handling steps.
Solution Approach 2:
The patent enables continuous manufacturing by implementing a liquid coating process that can be continuously applied and cured. Unlike discrete PET film application, the coating system allows for continuous coating of battery cells as they move through the manufacturing line, with UV curing immediately following application, creating an uninterrupted production flow.
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
The UV-curable coating ensures reliable adhesion and dielectric protection, reduces thermal impedance, and simplifies the manufacturing process by offering fast curing and robust edge coverage, maintaining adhesion even under harsh conditions (85°C and 85% RH) for up to 1000 hours, with a breakdown voltage of 5-10 kV at 100 microns thickness.
Implementation Method 1
UV curable coatings for dielectric insulation of battery packs
Implementation Method 2
exposing the curable coating to UV radiation, thereby forming a coated substrate
Data Source
AI summary
A UV curable dielectric coating is described. The curable coating can include one of more acrylate monomers, a urethane prepolymer, a crosslinker, at least one adhesion promoter, a photoinitiator, and optionally one or more fillers and/or additives. The coating can be used to insulate battery cells and battery packs, such as those used in electric vehicles. The coatings can be easily applied and quickly cured. The cured coatings can have high adhesion strength, even after exposure to wet conditions.