Battery Protective Case with Shielding Layer
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Solution Overview
Problem
Current battery protective cases lack adequate structural integrity and effective electromagnetic radiation shielding due to uneven plastic distribution and incorrect positioning of metal grids or shielding layers during production, leading to reduced impact resistance and incomplete radiation shielding.
Innovation Solution
A protective case for batteries featuring a multilayer structure with a resin matrix and a shielding layer made of conductive metal dispersed on polyester or non-woven polyester fabric, which is flexible and adaptable to different mold shapes, ensuring uniform shielding and structural integrity through co-extrusion or co-molding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a metal grid or shielding layer is inserted inside the plastic shell during production, then electromagnetic radiation shielding is provided, but the plastic material distribution becomes uneven creating weakening areas that reduce impact resistance
Solution Approach 1:
The patent combines the shielding layer and reinforcement layers into a single integrated multilayer structure that is co-extruded or co-molded as one piece. This merging eliminates the need to insert separate shielding components into the plastic shell, thereby avoiding uneven plastic distribution while maintaining both shielding effectiveness and structural strength.
Solution Approach 2:
The patent uses a composite multilayer structure consisting of alternating shielding layers (with metal particles) and reinforcement layers (with glass fibers or other reinforcements) embedded in a polymer matrix. This composite structure allows both electromagnetic shielding and mechanical strength to be achieved simultaneously through the synergistic combination of different materials and layers.
2Shape
If compression molding is used to form the protective case, then the desired shape is obtained, but the resin escapes during compression causing uneven distribution and reducing structural integrity
Solution Approach 1:
The patent prepares the multilayer structure with shielding and reinforcement layers before the molding process, pre-arranging them in the correct positions and orientations. This preliminary preparation ensures that when the resin is injected or co-extruded, it distributes evenly around the pre-positioned layers without escaping or creating voids, thereby maintaining manufacturing precision and structural integrity.
3Object-affected harmful factors
If individual layers are impregnated with resin and stacked, then the multilayer structure is formed, but the shielding layer slips within the mold creating areas with absent radiation shield
Solution Approach 1:
The patent merges the shielding layer and reinforcement layers into a single integrated multilayer structure that is co-extruded or co-molded as one piece. This eliminates the slippage problem entirely, as there are no separate layers to shift relative to each other during the molding process, ensuring precise positioning and complete radiation shielding coverage.
4Stability of the object's composition
If excess resin accumulates between layers during compression, then the layers are bonded, but deformities occur in the final product
Solution Approach 1:
The patent pre-pretes the multilayer structure with shielding and reinforcement layers before molding, ensuring proper spacing and alignment. This preliminary arrangement, combined with controlled resin injection or co-extrusion, prevents excess resin accumulation between layers, thereby avoiding deformities while maintaining layer cohesion through proper bonding.
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 provides effective shielding against electromagnetic radiation and enhanced structural integrity, allowing for various mold shapes and reducing production costs while maintaining high impact resistance and uniform resin distribution.
Implementation Method 1
a shielding layer (6) configured to shield electromagnetic radiation emitted by a battery and disposed between the first (4) and the second (5) reinforcement layers
Data Source
Figure 1~2
Figure 3
AI summary
Protective case for batteries (1) of vehicles comprising a resin matrix (2), a multilayer structure (3) embedded in the resin matrix (2) and configured to protect a battery, the multilayer structure (3) comprising at least one first reinforcement layer (4) and one second reinforcement layer (5). The multilayer structure (3) comprises a shielding layer (6) configured to shield the electromagnetic radiation emitted by the battery and disposed between the first (4) and second (5) reinforcement layers, the shielding layer (6) having a dispersion of metal material (7) characterized in that the shielding layer (6) comprises a polyester fabric with metal material (7) dispersed thereon or a polyester non-woven fabric with metal material (7) dispersed thereon.