Hot-Pressed Composite Battery Case for Lightweight Waterproof Packs

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Solution Overview

Problem

Existing new energy vehicle battery cases are overweight, complex to produce, and lack effective waterproofing, posing safety hazards due to water conductivity issues.

Innovation Solution

A battery case composed of resin-based composite material layers and waterproof layers bonded by hot pressing, eliminating the need for additional adhesives and simplifying the production process while providing excellent mechanical strength and waterproof performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If aluminum alloy tray and injection molded engineering plastics are used for battery case, then mechanical strength is improved, but weight increases and power consumption increases

Engineering Contradiction:

Improvemechanical strengthVSAvoidbattery weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent applies composite materials by combining aluminum alloy tray with waterproof coating layers and sealing structures. This creates a hybrid structure that maintains the mechanical strength of aluminum alloy while adding waterproof functionality, thereby resolving the contradiction between strength and weight by optimizing material composition rather than using单一 materials

Inventive Principle:

Principle #40Composite materials

2Stability of the object's composition

If completely enclosed structure is adopted for battery, then structural integrity is improved, but waterproof effect remains unsatisfactory

Engineering Contradiction:

Improvestructural integrityVSAvoidwaterproof effect

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The patent employs waterproof coating layers (such as waterproof film or coating applied on the inner wall of battery case) and sealing structures that act as flexible barriers. These thin film-like waterproof layers are integrated into the enclosed structure, maintaining structural integrity while providing reliable waterproof protection against water ingress

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The battery case uses composite construction combining the enclosed structural framework with waterproof coating materials and sealing elements. This composite approach ensures both structural integrity for mechanical strength and waterproof reliability by integrating multiple functional layers within the enclosed structure

Inventive Principle:

Principle #40Composite materials

3Reliability

If multiple layers of waterproof and water absorption materials are used, then waterproof performance is improved, but structure becomes complicated and productivity decreases

Engineering Contradiction:

Improvewaterproof performanceVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges multiple waterproof functions into integrated structures. Specifically, waterproof coating layers are directly applied and bonded to the battery case inner wall, and sealing structures are integrated into the case design. This consolidation achieves high waterproof performance while avoiding the complexity of separate stacked layers, thereby resolving the contradiction between waterproof reliability and structural simplicity

Inventive Principle:

Principle #5Merging (Combining)

4Reliability

If waterproof adhesive is applied to waterproof film, then waterproof effect is improved, but production process becomes complex and TVOC may exceed limits

Engineering Contradiction:

Improvewaterproof effectVSAvoidproduction process complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent extracts and eliminates the need for separate waterproof adhesives by using alternative bonding methods. Waterproof coating layers are directly bonded to the battery case through processes that do not require additional adhesive materials, thereby simplifying the production process and avoiding TVOC issues while maintaining waterproof effectiveness

Inventive Principle:

Principle #2Taking out (Extraction)

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 results in a lightweight, mechanically strong, and waterproof battery case with a simple structure, enhancing safety and production efficiency.

Implementation Method 1

the resin-based composite material layer and the waterproof layer are bonded to each other by hot pressing

Methodology Applied

Scientific EffectHot pressing:

Data Source

PatentUS20250023170A1Battery case and battery pack

Publication Date: 2025.01.16 BASF SE

AI summary

Disclosed herein is a battery case, which includes at least one resin-based composite material layer and at least one waterproof layer, where the resin-based composite material layer and the waterproof layer are bonded to each other by hot pressing. In addition, disclosed herein is a battery pack, which includes the battery case.