Wax-Coated EV Battery Module for Electrolyte Leak Corrosion Protection

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Solution Overview

Problem

Lithium ion battery electrolytes, particularly those containing fluorinated conductive salts, can escape and react with air humidity to form hydrofluoric acid, causing corrosive damage to vehicle bodies, especially in electric vehicles with multiple batteries where the risk of electrolyte leakage increases due to vibrations and housing failures.

Innovation Solution

A motor vehicle battery module with a protective layer applied to the outer housing and individual batteries to prevent electrolyte escape from contacting vehicle components, using a sprayable wax-based material that forms a thin, insulating, and thermally stable layer to shield against corrosion, and applying this layer to both the battery module and support structure to ensure comprehensive protection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If multiple individual batteries are used in a battery module, then the energy content increases, but the risk of electrolyte escape increases

Engineering Contradiction:

Improveenergy contentVSAvoidrisk of electrolyte escape

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The patent implements a nested protective structure where individual battery housings are placed within a battery module housing, which in turn is surrounded by a protective layer. This multi-layer nesting approach contains electrolyte at multiple levels, preventing escape even when individual components fail.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The protective layer acts as an intermediary barrier between the battery module and the vehicle body. This mediator prevents direct contact between escaped electrolyte constituents and the vehicle body, eliminating the harmful interaction while allowing the battery module to maintain high energy density.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If a protective layer is applied to the battery module, then corrosion protection is improved, but the device complexity increases

Engineering Contradiction:

Improvecorrosion protectionVSAvoidstructure complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent applies a thin-film protective layer (5-50 μm) that provides effective corrosion protection without adding significant structural complexity. This thin film approach maintains simplicity while delivering the required protective function against electrolyte constituents.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The protective layer is applied as a separate, extractable component that can be applied independently to the battery module and support structure. This modular approach allows corrosion protection to be added without redesigning the entire battery system, maintaining device simplicity.

Inventive Principle:

Principle #2Taking out (Extraction)

3Object-affected harmful factors

If the protective layer is applied to both the battery module and support structure, then comprehensive corrosion protection is achieved, but the manufacturing process becomes more complex

Engineering Contradiction:

Improvecomprehensive corrosion protectionVSAvoidmanufacturing process

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The protective layer is applied in advance during the manufacturing process, before the battery module is installed in the vehicle. This preliminary application ensures comprehensive protection is built-in from the start, eliminating the need for additional post-installation protection steps.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent combines the protective layer application for both the battery module and support structure into a unified manufacturing process. This merging of protection steps ensures consistent protection across all components while streamlining the overall manufacturing workflow.

Inventive Principle:

Principle #5Merging (Combining)

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 protective layer significantly reduces the risk of corrosion damage to the vehicle body by containing escaped electrolyte constituents, providing additional protection to adjacent batteries and ensuring the vehicle body remains corrosion-free over its lifespan.

Implementation Method 1

The protective layer significantly reduces the risk of corrosion damage to the vehicle body by containing escaped electrolyte constituents

Methodology Applied

Scientific EffectAdsorption: Adsorption

Implementation Method 2

using a sprayable wax-based material that forms a thin, insulating, and thermally stable layer to shield against corrosion

Methodology Applied

Scientific EffectDeposition: Deposition (physical)

Data Source

PatentUS12183937B2Motor vehicle battery module, motor vehicle having an electric drive motor and a battery module, and method for producing a motor vehicle battery module and a motor vehicle

Publication Date: 2024.12.31 PFINDER KG

AI summary

Motor vehicle battery modules having an energy content of at least 5 kWh for use as energy storage for electric cars. Such a battery module includes multiple individual batteries, each of which has at least one housing and at least one galvanic cell disposed within the housing. The battery module further includes a joining device, by which the individual batteries are assembled to form a battery module that can be handled as a whole. The battery module has, on its outside, a spray-applied protective layer that includes a wax and surrounds at least sections of the battery module.