Plastic Battery Housing Shell With Integrated Thermal Barrier
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Solution Overview
Problem
Battery housing shells for traction batteries in electric and hybrid vehicles face challenges in thermal stability due to the high energy density of lithium-ion batteries, leading to potential thermal runaway and the need for improved temperature resistance without increasing manufacturing costs.
Innovation Solution
A battery housing shell with a high-temperature-resistant protective device integrated into the plastic structure, which is form-fit engaged by the shell's wall during manufacturing, using materials like thermoplastic or thermosetting plastics and reinforced with fibers, and potentially metal or ceramic, to enhance thermal and mechanical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a plastic battery housing shell is used to reduce weight and manufacturing costs, then manufacturing costs are reduced, but temperature resistance and thermal stability deteriorate
Solution Approach 1:
The patent applies composite materials by combining plastic with high-temperature-resistant materials (such as metal or ceramic) to create a hybrid structure. The plastic provides lightweight properties and cost benefits, while the embedded high-temperature-resistant material provides thermal stability and resistance to thermal runaway, thus resolving the contradiction between manufacturing cost and temperature resistance.
Solution Approach 2:
The patent embeds a high-temperature-resistant protective device within the plastic battery housing shell structure. The protective device is positioned inside the plastic housing, creating a nested configuration where the inner protective element enhances thermal resistance while the outer plastic housing maintains cost-effectiveness and lightweight properties.
2Temperature
If a high-temperature-resistant protective device is added to improve thermal stability, then temperature resistance is improved, but device complexity increases
Solution Approach 1:
The patent merges the protective device with the battery housing shell into a single integrated structure. The high-temperature-resistant protective device is embedded during the molding process, combining two functional elements (housing and protection) into one component, thereby reducing assembly steps and overall device complexity while maintaining enhanced thermal resistance.
Solution Approach 2:
The protective device is pre-positioned and integrated into the housing structure during the molding process itself, rather than being added as a separate post-assembly component. This preliminary integration simplifies the overall device structure and reduces the number of assembly operations required.
3Temperature
If a separate protective device is added after manufacturing to improve thermal resistance, then temperature resistance is improved, but manufacturing time increases
Solution Approach 1:
The protective device is combined with the housing manufacturing process, allowing both components to be produced simultaneously in one operation. This eliminates the need for separate assembly steps and reduces total manufacturing time while ensuring the protective device is properly integrated into the final product.
Solution Approach 2:
The protective device is pre-positioned in the mold cavity before the plastic material is injected, allowing it to be integrated into the housing during the molding process itself. This preliminary placement ensures the protective device is ready before final assembly, eliminating post-manufacturing installation steps and reducing overall production time.
Data Source
AI summary
A battery housing shell for a battery housing of a traction battery for accommodating at least one battery component in a battery housing volume. A wall of the battery housing shell at least partially limits the battery housing volume and the wall of the battery housing shell is at least partially formed from a plastic. The battery housing shell includes a high-temperature-resistant protective device that is at least partially form-fit engaged from behind by the wall of the battery housing shell.