Multilayer Battery Pack Insulator Sheet for Impact Short-Circuit Isolation
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Solution Overview
Problem
Electric vehicle battery packs are prone to short-circuiting due to impact forces that deform the vehicle body panel, causing the metal mount bracket to penetrate the battery cover and contact conductive components, especially in humid environments where fluid or moisture can facilitate the short-circuit.
Innovation Solution
A multilayer, flexible, impact and puncture-resistant dielectric insulator sheet is used, comprising a textile layer with a fluid impervious polyethylene terephthalate film bonded by an adhesive laminate, which is designed to prevent fluid passage and protect the battery pack from short-circuits by being placed between the metal mount bracket and the battery pack.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal mount bracket is used to secure the battery pack to the body panel, then the battery pack is firmly fixed, but the bracket can penetrate the battery cover and contact conductive components causing short-circuit upon impact
Solution Approach 1:
A dielectric insulator sheet is introduced as an intermediary component between the metal mount bracket and the battery pack. This insulator sheet prevents direct contact between the conductive bracket and conductive bus bars, eliminating the short-circuit pathway while maintaining the mechanical fixation function of the bracket.
Solution Approach 2:
The insulator sheet employs a composite structure combining a textile layer for mechanical strength and impact resistance with a fluid impervious film for moisture barrier properties. This composite material provides both structural integrity and electrical insulation, addressing multiple requirements simultaneously.
2Strength
If the battery pack is secured with fasteners through the body panel, then the battery pack is firmly mounted, but impact forces can deform the body panel and cause the bracket to penetrate the battery cover
Solution Approach 1:
The insulator sheet is positioned beforehand between the mount bracket and battery pack to provide cushioning and protection. Upon impact, the insulator sheet absorbs and distributes the force, preventing the bracket from penetrating the battery cover and protecting the internal components.
3Ease of manufacture
If the insulator sheet uses a single-layer structure, then the manufacturing is simpler, but it cannot provide both impact resistance and fluid imperviousness simultaneously
Solution Approach 1:
The insulator sheet uses a composite structure combining a textile layer for mechanical strength and impact resistance with a fluid impervious film for moisture barrier properties. This composite material provides both structural integrity and electrical insulation, addressing multiple requirements simultaneously.
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 effectively inhibits short-circuiting by preventing fluid and moisture transfer, maintaining the integrity of the battery pack during impacts and ensuring electrical insulation, even in high humidity conditions, while being adaptable and economical in various configurations.
Implementation Method 1
The fluid impervious film is fixed to the first side with an adhesive layer
Implementation Method 2
a fluid impervious film fixed to the first side... impervious to the passage of fluid therethrough
Implementation Method 3
dielectric insulator sheet for an electric vehicle battery pack... ensuring electrical insulation
Data Source
AI summary
A multilayer, flexible, impact and puncture resistant, impervious, dielectric insulator sheet and mounting arrangement therewith for an electric vehicle battery pack includes a textile layer having generally planar opposite first and second sides and a fluid impervious film fixed to the first side with an adhesive laminate. The adhesive laminate includes a polymeric film sandwiched between opposite first and second layers of adhesive material. The first layer of adhesive material is bonded to the textile layer and the second layer of adhesive material is bonded to the fluid impervious film.