EMI-Shielded Composite Battery Enclosures for Collision Protection
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Solution Overview
Problem
Large capacity batteries in electric vehicles are vulnerable to damage during collisions, necessitating protective enclosures that are both strong and lightweight, while also shielding against electromagnetic interference.
Innovation Solution
Composite battery enclosures with electromagnetic shielding properties, featuring a molded top and bottom composite covers sandwiching cores, incorporating conductive fillers or layers to absorb, reflect, or attenuate electromagnetic interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If large capacity batteries are used to supply power for long distances, then the power and energy of the vehicle are improved, but the risk of battery damage during collision increases
Solution Approach 1:
The patent applies beforehand cushioning by incorporating energy-absorbing structures within the battery enclosure design. These structures are pre-configured to deform and absorb impact energy during collision events, protecting the battery cells from damage before the force reaches critical levels. The enclosure includes sacrificial elements that fail in a controlled manner to dissipate collision energy.
Solution Approach 2:
The patent employs composite materials for the battery enclosure structure, combining materials with different mechanical properties to achieve both strength and energy absorption. The enclosure uses composite panels that can withstand collision forces while protecting the battery, integrating multiple material functions into a single structural system.
2Strength
If traditional battery enclosures are used to protect batteries from collision forces, then the structural strength is improved, but the weight of the enclosure increases
Solution Approach 1:
The patent uses composite materials for the battery enclosure to achieve high strength-to-weight ratio. The composite structure provides adequate protection against collision forces while maintaining lower weight compared to traditional solid metal enclosures. The composite panels incorporate reinforcement patterns that enhance structural strength without adding excessive weight.
Solution Approach 2:
The enclosure structure is segmented into multiple functional zones with different thicknesses and material compositions. High-strength materials are concentrated in areas subject to collision forces, while lighter materials are used in non-critical areas. This segmentation allows optimization of weight distribution and structural efficiency.
3Strength
If battery enclosures are designed for mechanical protection only, then the collision resistance is improved, but the electromagnetic compatibility is worsened
Solution Approach 1:
The battery enclosure is designed with multi-functionality, serving both mechanical protection and electromagnetic shielding purposes. The same structural panels that provide collision resistance also incorporate electromagnetic compatibility features through conductive coatings or filler materials, eliminating the need for separate shielding layers and maintaining structural integrity while blocking electromagnetic interference.
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
Provides effective electromagnetic shielding and structural protection, ensuring battery safety and reducing the risk of damage during collisions, while maintaining a lightweight and cost-effective manufacturing process.
Implementation Method 1
The molded top composite cover, the molded bottom composite cover, or both, include an electromagnetic shielding resin matrix, the electromagnetic shielding resin matrix including a dispersed conductive filler
Data Source
AI summary
A molded composite battery enclosure containing top and bottom composite covers attached together. The joined top and bottom composite cover structures form an enclose or open area for housing a battery system of battery cells and cooling devices. The composite battery enclosures are lightweight and made of materials that can function to absorb energy and insulate the battery housing area. The composite structures contain a core material adhered and sandwiched between skin fiber layers and an electromagnetic shielding material or resin incorporated into one of the composite structures.