Multi-Layer Battery Housing Cover for Vibration-Resistant Rigidity
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Solution Overview
Problem
Housing covers for traction batteries in electric vehicles face challenges due to disruptive oscillation behavior and the need for additional connection points for stabilization, which increases production complexity and loses construction space.
Innovation Solution
A multi-layer housing part, specifically a housing cover, composed of an outer plastic layer, a metal layer with a steel inlay, a structural layer with a high elasticity modulus, and an intermediary layer, which distributes loads and reduces oscillations without the need for additional bracing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If additional connection points and stiffening beads are added to stabilize the housing cover, then the oscillation behavior and endurance strength are improved, but the construction space inside the battery is reduced and the manufacturing complexity increases
Solution Approach 1:
The housing cover uses a composite structure combining a plastic outer layer with a metal layer (steel inlay) that is over-molded or poured into the plastic material. This composite construction provides enhanced rigidity and oscillation resistance without requiring additional stiffening beads, thereby preserving construction space inside the battery housing.
Solution Approach 2:
The housing cover is divided into functional layers: an outer plastic layer for corrosion protection and thermal insulation, and an integrated metal layer for structural rigidity and load bearing. This segmentation allows each layer to perform its specific function optimally without requiring additional connection points or bracing elements.
2Strength
If additional connection points and stiffening beads are added to stabilize the housing cover, then the oscillation behavior and endurance strength are improved, but the manufacturing effort and complexity increase
Solution Approach 1:
The metal layer is integrated directly into the plastic housing cover through over-molding or pouring processes, combining structural reinforcement and corrosion protection into a single manufacturing step. This eliminates the need for separate stiffening beads and additional connection points, reducing manufacturing complexity while maintaining high endurance strength.
3Stability of the object's composition
If additional connection points are added to stabilize the housing cover, then the oscillation behavior is improved, but the construction space inside the battery is reduced
Solution Approach 1:
The integrated metal-plastic composite structure provides inherent oscillation resistance through the combined properties of the rigid metal layer and the protective plastic layer, eliminating the need for additional connection points that would otherwise occupy space inside the battery housing.
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 multi-layer construction enhances the inherent rigidity of the housing part, reduces oscillations and noise, and conserves construction space by eliminating the need for additional bracing, thereby simplifying production and maintenance.
Implementation Method 1
The outer layer and the metal layer are connected over a large surface area... The structural layer covers at least one part of a surface of the outer layer and/or the metal layer... An intermediary layer is arranged between the structural layer and the combination of the outer layer and metal layer
Implementation Method 2
A multi-layer housing part, specifically a housing cover, composed of an outer plastic layer, a metal layer with a steel inlay, a structural layer with a high elasticity modulus, and an intermediary layer, which distributes loads and reduces oscillations
Data Source
AI summary
A housing cover for a battery housing of a traction battery of an electrically operable vehicle is designed to connect to a second housing part of the battery housing. The cover has a construction of several layers with different materials, including an outer layer made of a plastic, a metal layer made of steel, and a structural layer made of a structural material. The outer layer and the metal layer are connected over a large area. The structural layer covers at least one part of a surface of the outer layer and/or the metal layer. An intermediary layer is arranged between the structural layer and the combination of outer layer and metal layer.