Battery Housing Metal Foil Coating for Heat-Resistant EV Packs
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Solution Overview
Problem
Existing high-voltage battery units for vehicles face challenges in achieving high operational safety, particularly in extreme situations such as serious accidents, without compromising weight, production costs, or altering the basic geometry of the housing.
Innovation Solution
Coating the interior sides of the high-voltage battery housing with a heat-resistant metal foil, which is thin and cost-effective, enhancing thermal resistance and maintaining the lightweight character while allowing for flexible connection and decoupling of components to prevent slipping during thermal expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the housing wall thickness is increased to improve heat resistance, then thermal protection improves, but weight increases and lightweight character is lost
Solution Approach 1:
The patent applies a thin metal foil (stainless steel, aluminum, or other heat-resistant metal) as an internal coating layer on the housing walls. This thin film provides effective thermal protection without requiring substantial increases in housing wall thickness, thereby maintaining the lightweight character of the battery housing while achieving the desired heat resistance.
Solution Approach 2:
The patent creates a composite structure by combining the existing housing material (light metal or plastic) with a thin metal foil layer. This composite approach allows the housing to benefit from both the structural properties of the original material and the thermal protection of the metal foil, achieving heat resistance without sacrificing weight efficiency.
2Temperature
If heat-resistant materials such as fire protection paints are used, then thermal protection improves, but production costs increase significantly
Solution Approach 1:
The patent uses thin metal foils (such as stainless steel foil or aluminum foil) as a cost-effective alternative to expensive fire protection paints. These foils can be applied internally to the housing walls in a simple manner, providing effective thermal protection at significantly lower production costs compared to conventional fire protection coatings.
3Temperature
If the basic concept or geometry of the housing is substantially changed to improve heat resistance, then thermal protection improves, but production complexity and costs increase
Solution Approach 1:
The patent applies the heat-resistant metal foil coating to the internal surfaces of the existing housing structure without requiring substantial changes to the basic concept or geometry of the housing. This preliminary protective layer is applied to the finished housing, allowing thermal protection to be achieved while maintaining the original design and geometry.
4Reliability
If a flexible contact element is introduced between components and the metal foil, then prevention of slipping during thermal expansion is achieved, but device complexity increases
Solution Approach 1:
The patent introduces a flexible contact element (such as a flexible cable or flexible connector) between movable components and the metal foil coating. This flexible element can accommodate thermal expansion and contraction of the housing and components during operation, preventing stress concentration and potential slipping or detachment of the metal foil while maintaining operational safety.
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 method significantly increases the heat resistance and safety of the battery unit, ensuring operational integrity even in extreme conditions, while retaining lightweight and cost-effective design.
Implementation Method 1
The heat resistance of the high-voltage battery housing can be significantly increased by coating the housing walls of the high-voltage battery housing with a heat-resistant metal foil
Implementation Method 2
The metal foil is preferably connected to the housing in an electrically conductive manner
Data Source
AI summary
A method for producing a high-voltage battery unit, particularly for vehicles, includes producing a housing, which has a plurality of housing walls coating interior sides of the housing walls with a heat-resistant metal foil, introducing an electrical battery and cooling system into the housing, and sealing the housing.