Battery Enclosure Composite Layers for Fire and EMI Shielding
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Solution Overview
Problem
Existing battery enclosures lack effective fire retardation and shielding capabilities, posing risks to safety and performance.
Innovation Solution
A composite system comprising a flame-retarding layer and a shielding layer, where the flame-retarding layer includes a molding formulation and fiber, and the shielding layer includes a metallic fabric, is used to form a battery enclosure through compression molding, providing both fire retardation and shielding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single-layer enclosure structure is used, then manufacturing simplicity is maintained, but fire retardation and shielding capabilities are insufficient
Solution Approach 1:
The enclosure is divided into distinct functional layers: a flame-retarding layer containing flame-retardant additives and fibers for fire protection, and a shielding layer with metallic fabric for EMI/RFI shielding. This segmentation allows each layer to optimize its specific function while collectively providing comprehensive protection that a single-layer structure cannot achieve.
Solution Approach 2:
The invention employs composite material construction by combining different materials with complementary properties - flame-retardant polymers and fibers in the first layer, and metallic fabric in the second layer. This composite approach enables simultaneous achievement of fire retardation and electromagnetic shielding capabilities that neither material could provide alone.
2Reliability
If multiple functional layers are integrated, then fire retardation and shielding performance are improved, but manufacturing complexity increases
Solution Approach 1:
The invention merges multiple manufacturing operations into a single co-molding process where both the flame-retarding layer and shielding layer are formed and bonded simultaneously in one manufacturing cycle. This integration eliminates the need for separate molding, handling, and assembly steps that would otherwise be required for multiple layers, thereby maintaining ease of manufacture despite the increased functional complexity.
Solution Approach 2:
The co-molding process serves multiple functions simultaneously: it forms both structural layers, provides bonding between layers through integrated resin flow, and achieves final part geometry in a single operation. This multi-functionality of the manufacturing process offsets the increased complexity introduced by the multi-layer structure.
3Object-affected harmful factors
If flame-retarding materials are used, then fire safety is improved, but material cost and processing complexity increase
Solution Approach 1:
Flame-retardant additives and fire-resistant fibers are concentrated specifically in the flame-retarding layer where they are most needed for fire protection, rather than distributing them throughout the entire enclosure structure. This localized application achieves fire safety requirements while minimizing the overall complexity and cost of the molding formulation.
Data Source
AI summary
A composite system and methods for using and preparing a composite system including a flame-retarding layer and shielding layer is described.