Battery Cover Spacer Design for Thermal Insulation
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Solution Overview
Problem
Existing battery covers do not adequately protect vehicle batteries from heat, as heat conducted to the cover is not effectively insulated from reaching the battery fluid, leading to reduced battery lifespan.
Innovation Solution
A battery cover design featuring side walls that cover all four sides of the battery, with spacers at the top and bottom to create an air gap, and second spacers that contact the battery's corners for secure attachment, along with a heat-insulating material and air intake mechanism for enhanced cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the inner wall is brought into close contact with the side faces of the battery, then the structural stability is improved, but the heat insulation performance deteriorates
Solution Approach 1:
A heat-insulating material is introduced as an intermediary layer between the inner wall and the battery side faces. This material fills the gaps and spaces formed by the frame-shaped cover main body, preventing direct thermal contact while maintaining structural stability. The heat-insulating material acts as a thermal barrier that blocks heat conduction paths without compromising the mechanical support provided by the frame structure.
2Ease of manufacture
If the battery cover is made with a frame-shaped cover main body, then the manufacturing cost is reduced, but the heat insulation performance deteriorates
Solution Approach 1:
The invention merges two different approaches: the cost-effective frame-shaped cover main body made from bent resin board and the thermal protection provided by heat-insulating material. By combining these elements, the solution achieves both economical manufacturing (through the simple frame structure) and effective heat insulation (through the added insulating material that fills the frame's spaces).
Solution Approach 2:
The battery cover becomes a composite structure consisting of the frame-shaped cover main body (structural component) and the heat-insulating material (functional component). This composite approach allows each material to perform its specialized function - the frame provides mechanical support while the insulating material provides thermal protection - resulting in a cost-effective and performance-optimized solution.
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 design provides excellent heat-insulating properties, effectively protecting the battery from external heat and ensuring reliable attachment, while the air intake mechanism aids in quick cooling, thus extending battery life.
Implementation Method 1
This configuration allows for generation of a space (air layer) between the side faces of the battery and the battery cover. Therefore, the heat conducted from outside to the side walls of the battery cover is not conducted directly to the battery side faces through the battery cover.
Data Source
Figure 1
Figure 2
Figure 3(a)~3(b)
AI summary
A battery cover includes side walls that cover four side faces of the battery, and a first spacer provided at a top portion of the side walls for providing a space between the battery and the side wall.