Battery Housing Composite Shielding Design
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Solution Overview
Problem
Existing battery housings face challenges with insufficient electromagnetic compatibility and complex, costly production processes, particularly due to undesirable electrical and electromagnetic interactions between metal housings and battery cells.
Innovation Solution
A battery housing design featuring multiple plastic housing parts with metal layers applied for electromagnetic shielding, where the metal layers contact each other in the connection areas, creating an electromagnetically shielded inner volume while simplifying manufacturing by reducing the need for separate electrical insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal housing is used for battery housing, then mechanical stability is improved, but electromagnetic compatibility deteriorates due to electrical and electromagnetic interactions with battery cells
Solution Approach 1:
The housing uses a composite structure combining plastic base material with applied metal layers. This allows the housing to benefit from the mechanical stability of metal while the plastic provides electrical insulation, and the metal layers provide electromagnetic shielding, thus resolving the contradiction between mechanical strength and electromagnetic compatibility
2Strength
If a metal housing is used for battery housing, then mechanical stability is improved, but production complexity increases due to the need for separate electrical insulation
Solution Approach 1:
The invention merges multiple functions into a single housing structure: the plastic base provides structural support and electrical insulation, while integrated metal layers provide electromagnetic shielding. This consolidation eliminates the need for separate insulation components and simplifies the production process while maintaining mechanical stability
3Reliability
If plastic housing parts with metal layers are used, then electromagnetic compatibility is improved, but manufacturing complexity increases due to metal layer application processes
Solution Approach 1:
The housing is divided into multiple plastic parts that are separately manufactured and then assembled. The metal layers are applied to individual parts rather than the complete housing, allowing for simpler manufacturing processes and easier assembly while maintaining effective electromagnetic shielding across the entire housing structure
4Reliability
If metal layers extend into connection areas of housing parts, then electromagnetic shielding is improved, but manufacturing precision requirements increase
Solution Approach 1:
The metal layers are strategically extended into the connection areas where electromagnetic shielding is most critical. Rather than requiring uniform high precision across the entire housing, the design focuses metal layer placement on specific local regions (connection areas) where it provides maximum shielding benefit, thereby reducing overall manufacturing precision requirements
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 design enhances electromagnetic compatibility and simplifies production by ensuring improved shielding without additional insulation, leading to a more cost-effective and efficient battery housing solution.
Implementation Method 1
a metal layer (9) applied to the base body (8) for electromagnetic shielding of the inner volume (7)
Implementation Method 2
The respective metal layer (9) extends into the connecting section (10) of the associated housing part (5, 6), so that the metal layers (9) contact each other in the connecting sections (10) resting on one another
Data Source
AI summary
A battery housing for accommodating battery cells of a battery may include at least two housing parts delimiting an inner volume. Each housing part of the at least two housing parts may have a connecting section. The connecting sections of the at least two housing parts may rest on one another. The at least two housing parts may be connected to one another via the connecting sections. Each housing part may have a plastic base body and a metal layer disposed on the base body for electromagnetic shielding of the inner volume. The metal layer may extend into the connecting section of the corresponding housing part such that the metal layers, in the connecting sections resting on one another, contact each other along an extension of the connecting sections.