Battery Damping Element With Foam Coupling for Sheet Metal Vibration
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Solution Overview
Problem
Existing damping solutions for motor vehicle batteries in electric vehicles fail to effectively couple the battery mass to the vehicle floor, leading to inadequate vibration damping of sheet metal, and do not provide corrosion resistance or electromagnetic radiation shielding.
Innovation Solution
A viscoelastic PUR foam damping element with a nonwoven cover and vent openings, compressed between the battery system and the vehicle floor, which couples the battery mass to the car body sheet metal, reducing vibrations and offering corrosion resistance and electromagnetic shielding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a damping element is arranged between the battery system and the vehicle floor to couple the battery mass and reduce sheet metal vibrations, then vibration damping is improved, but the device complexity increases due to the need for additional components with multiple functions (damping, corrosion protection, electromagnetic shielding)
Solution Approach 1:
The patent combines multiple protective functions into a single integrated damping element. The viscoelastic foam core provides vibration damping, while the nonwoven cover simultaneously offers corrosion protection and electromagnetic radiation shielding. This merging of functions into one component resolves the technical contradiction by achieving multiple protective effects without requiring separate layers or components for each function.
Solution Approach 2:
The damping element uses a composite structure consisting of a viscoelastic foam material (PUR foam with specific density and loss factor) combined with a nonwoven cover material. This composite construction allows the element to exhibit multiple properties: vibration damping from the viscoelastic foam, corrosion resistance from the nonwoven cover, and electromagnetic shielding from the conductive coating on the nonwoven. The composite material approach enables simultaneous achievement of multiple protective functions.
2Object-affected harmful factors
If the foam is compressed in the range from 25 to 75% between the battery system and the vehicle floor, then the coupling effect and vibration damping are improved, but the foam thickness and available space are reduced
Solution Approach 1:
The patent specifies optimal compression parameters for the foam (25-75% compression ratio) to achieve the best damping effect. By controlling the compression within this range, the foam maintains sufficient thickness while achieving effective coupling between the battery mass and vehicle floor. The viscoelastic properties of the foam (loss factor > 0.2) are optimized to provide maximum damping within the available space constraints.
3Object-affected harmful factors
If the nonwoven is coated with copper or aluminium to provide electromagnetic radiation shielding, then electromagnetic shielding is improved, but the manufacturing complexity and corrosion protection requirements increase
Solution Approach 1:
The patent uses a nonwoven material as a substrate for the conductive coating. The porous structure of the nonwoven provides a large surface area for the copper or aluminium coating, enhancing electromagnetic shielding effectiveness. The nonwoven also serves as a corrosion-resistant barrier that protects the conductive coating from environmental degradation, simplifying the overall manufacturing process by combining structural support, corrosion protection, and electromagnetic shielding in one integrated component.
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 solution significantly reduces sheet metal vibrations, allowing for weight reduction by eliminating the need for anti-drumming foils, while ensuring corrosion resistance and electromagnetic radiation shielding.
Implementation Method 1
a viscoelastic PUR foam 1 with (a) a density in the range 20 to 65 kg/m3, (b) a loss factor greater than 0.2
Implementation Method 2
reduces/dampens the sheet metal vibrations
Implementation Method 3
the nonwoven 2 is coated on the side facing away from the foam 1... suitable for shielding electromagnetic radiation
Implementation Method 4
this damping element 4 is arranged in a compressed manner in the range from 25 to 75% between the battery/battery system and the motor vehicle floor
Implementation Method 5
couples the mass of the battery/accumulator system to the motor vehicle floor
Data Source
AI summary
A damping element for a battery/accumulator system is arranged between the battery/battery system and a floor of a motor vehicle.