Organic Coated Battery Casing with Cold-Hardening Adhesive

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Solution Overview

Problem

Existing battery housings for vehicle batteries face challenges in manufacturing complexity and high costs due to the need for cathodic dip painting for corrosion protection and thermal joining methods, which are complex and costly.

Innovation Solution

The use of organically coated sheet metal housing sections connected via a corrosion-resistant connecting element using a cold-hardening adhesive, eliminating the need for subsequent painting and thermal joining, while ensuring high corrosion protection and structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If cathodic dip painting (KTL) is used for corrosion protection, then corrosion protection is improved, but process and logistics costs increase

Engineering Contradiction:

Improvecorrosion protectionVSAvoidprocess and logistics costs

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The housing sections are pre-coated with organic coating before assembly, eliminating the need for post-assembly painting. This preliminary action allows corrosion protection to be applied to individual sections in a controlled manner before they are joined together, reducing the complexity of the overall manufacturing process

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The battery housing is divided into multiple separate housing sections that are coated individually and then assembled. This segmentation allows each section to be coated independently before assembly, avoiding the need for complex post-assembly painting operations on the complete housing structure

Inventive Principle:

Principle #1Segmentation

2Strength

If thermal joining methods are used to connect housing sections, then structural integrity is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvestructural integrityVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent replaces thermal joining methods with mechanical fastening systems. Fasteners such as screws, clips, or interlocking mechanisms are used to connect housing sections, eliminating the need for complex thermal processing equipment and procedures while maintaining structural integrity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

Fastening elements serve as intermediaries between housing sections, providing a simple mechanical connection that avoids direct thermal contact. These intermediaries enable assembly without requiring the housing materials to undergo thermal processing

Inventive Principle:

Principle #24Intermediary (Mediator)

3Strength

If thermal joining is used to connect housing sections, then structural integrity is improved, but the organic coating is damaged or destroyed

Engineering Contradiction:

Improvestructural integrityVSAvoidcoating damage

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

Mechanical fastening methods are used instead of thermal joining, completely avoiding the application of heat that would damage the organic coating. The mechanical connection achieves structural integrity without exposing the coating to temperatures that cause degradation

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Reliability

If housing sections are made from organically coated sheet metal, then corrosion protection is improved, but manufacturing flexibility is reduced

Engineering Contradiction:

Improvecorrosion protectionVSAvoidmanufacturing flexibility

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The organic coating is applied to sheet metal sections before they are cut, formed, or assembled. This preliminary coating ensures that all surfaces requiring corrosion protection are covered before manufacturing operations, and the coating can be selected to withstand subsequent forming and assembly processes

Inventive Principle:

Principle #10Preliminary action

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 approach simplifies and cost-reduces the manufacturing process while maintaining high strength and tightness, ensuring effective corrosion protection without damaging the organic coating, suitable for harsh environmental conditions.

Implementation Method 1

The interconnected housing sections are made from an organically coated sheet metal from an at least neighboring beard and glued to a connecting element on the feet

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

The organic coating ensures high corrosion protection, so that no complex painting of the housing sections is required

Methodology Applied

Scientific EffectCorrosion protection: Coatings

Data Source

PatentEP4096000A1Battery casing

Publication Date: 2022.11.30 FRIEDRICH BOYSEN GMBH & CO KG

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AI summary

A battery housing for an electrical energy storage device defines, at least in sections, a receiving space for the electrical energy storage device and has at least two housing sections that are joined together at a joint. The at least two joined housing sections are made of sheet metal that is organically coated at least adjacent to the joint and are bonded at the joint with a connecting element.