Composite Battery Box for Lightweight Thermal Management
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Solution Overview
Problem
Existing battery compartments in electric and hybrid vehicles face issues with weight, durability, and thermal transfer efficiency, particularly when exposed to extreme temperatures and humidity, and require improved protection against impact and fire risks.
Innovation Solution
A battery compartment made of a composition comprising reinforcing fibers, thermoconductive components, impact modifiers, and a polyamide matrix, with a heat transfer fluid inlet and outlet, designed to provide lightweight, durable, and efficient thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal compartment is used for the battery, then the structural strength and protection are improved, but the weight increases and thermal transfer efficiency decreases
Solution Approach 1:
The patent employs a composite material consisting of a thermoplastic matrix (polyamide, polypropylene, or polyethylene) reinforced with mineral fibers (glass, carbon, or basalt fibers). This composite structure provides the necessary mechanical strength and rigidity while maintaining a significantly lower weight compared to traditional metal compartments. The fiber reinforcement compensates for the lower inherent strength of polymers, creating a lightweight yet durable battery enclosure.
2Strength
If a metal compartment is used for the battery, then the structural strength is improved, but the manufacturing complexity increases for complex shapes
Solution Approach 1:
The patent utilizes the thermoplastic nature of the matrix material to enable complex geometries through injection molding or similar forming processes. The material can be molded into intricate shapes that would be difficult or expensive to manufacture from metal, while the fiber reinforcement maintains structural integrity. This allows for optimized battery compartment designs that adapt to various vehicle layouts and battery configurations.
3Duration of action of stationary object
If a metal compartment is used for the battery, then the durability is improved, but the corrosion resistance in humid environments decreases
Solution Approach 1:
The composite material system combines corrosion-resistant thermoplastic matrices with inert mineral fiber reinforcements (particularly glass and carbon fibers). This creates a battery enclosure that is inherently resistant to corrosion from moisture, salt, and other environmental contaminants, eliminating the rust and degradation issues associated with metal compartments while maintaining long-term durability in harsh automotive environments.
4Weight of moving object
If the compartment material is changed to reduce weight, then the weight is reduced, but the thermal transfer efficiency decreases
Solution Approach 1:
The patent strategically combines materials with complementary thermal properties: the thermoplastic matrix provides thermal insulation to protect surrounding components, while the mineral fiber reinforcement (particularly carbon and glass fibers) creates thermal pathways for efficient heat dissipation from the battery. This dual-function composite structure enables effective thermal management while maintaining lightweight construction.
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 offers improved thermal transfer efficiency, enhanced durability, and resistance to environmental stresses while meeting safety and shape variability requirements, contributing to energy efficiency and safety in electric vehicles.
Implementation Method 1
0 to 20% by weight in relation to the total weight of at least one thermoconductive component
Implementation Method 2
a heat transfer fluid inlet; and a heat transfer fluid outlet
Data Source
AI summary
A device for cooling and/or heating a battery of an electric or hybrid motor vehicle, including a battery box provided with: at least one envelope of a composition including between 0 and 80 wt. %, in relation to the total weight of the composition, of reinforcing fibres, between 0 and 20 wt. %, in relation to the total weight, of at least one thermoconductive component, between 0 and 20 wt. %, in relation to the total weight, of at least one impact modifier, and between 0 and 20 wt. %, in relation to the total weight of the composition, of additives, the remainder being a matrix predominantly including at least one polyamide and optionally at least one flameproofing agent; an inlet for a heat-transfer fluid; and an outlet for a heat-transfer fluid, the box defining a battery cooling and/or heating space.