Composite Battery Cover Integrating Fire Retardant and Conductive Shielding
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Solution Overview
Problem
High-voltage vehicle batteries pose a growing hazard due to increased energy content and voltage, with conventional plastic and metal covers failing to provide adequate fire protection and electromagnetic shielding while maintaining a compact and lightweight design, and existing solutions complicate installation and increase production costs.
Innovation Solution
A composite cover made of a polymer matrix with embedded fire retardant materials and an electrically conductive layer, which integrates fire protection and electromagnetic shielding, eliminating the need for air gaps and allowing for a compact, lightweight, and cost-effective design that simplifies installation and production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional plastic covers are used, then weight is reduced, but fire protection is insufficient
Solution Approach 1:
The cover is made from a composite material consisting of a polymer matrix and fire-retardant materials embedded therein. This composite structure provides both the weight advantages of plastic and the fire protection properties of fire-retardant materials, resolving the contradiction between weight reduction and fire safety.
2Reliability
If full-metal covers are used, then fire protection is improved, but weight increases
Solution Approach 1:
Instead of using full-metal covers, the invention employs a composite material with a polymer matrix and embedded fire-retardant materials. This provides sufficient fire protection while maintaining significantly lower weight compared to metal alternatives.
3Reliability
If metallic materials are used for electromagnetic shielding, then shielding effectiveness is improved, but device complexity and space requirement increase due to additional air gaps and creeping distances
Solution Approach 1:
The cover integrates multiple functions into a single component: structural closure, fire protection through embedded fire-retardant materials, and electromagnetic shielding through a conductive layer. This eliminates the need for separate shielding components and associated air gaps, reducing structural complexity while maintaining shielding effectiveness.
Solution Approach 2:
The composite structure combines a polymer matrix with a conductive layer for electromagnetic shielding. This integrated approach provides shielding effectiveness without requiring the additional air gaps and creeping distances needed when separate metallic shielding components are used.
4Reliability
If separate components for fire protection and electromagnetic shielding are used, then each function is optimized, but manufacturing complexity and production costs increase
Solution Approach 1:
The invention combines fire protection and electromagnetic shielding functions into a single integrated cover component. The polymer matrix provides the base structure, fire-retardant materials are embedded within it, and a conductive layer is applied for electromagnetic shielding. This single-component approach simplifies manufacturing and assembly compared to using multiple separate components.
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 composite cover effectively addresses fire protection and electromagnetic compatibility, reducing weight and installation complexity while ensuring safety and cost savings by integrating fire retardant and conductive features into a single component, thereby enhancing safety and reducing production costs.
Implementation Method 1
the composite material comprises a polymer matrix and an at least fire retardant material embedded in said matrix
Implementation Method 2
the cover has an electrically conductive layer which forms an electromagnetic shield
Data Source
AI summary
A cover for a battery housing of a high-voltage vehicle battery. The cover includes a composite material which for its part comprises a polymer matrix and an at least fire retardant material embedded in said polymer matrix. In addition, the cover includes an electrically conductive layer which forms an electromagnetic shield.