Composite Battery Enclosure Laminate for Thermal and EMI Shielding

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Solution Overview

Problem

Existing battery enclosures made of metal are heavy and do not effectively combine structural support with thermal insulation, fire resistance, and electromagnetic shielding.

Innovation Solution

A battery enclosure featuring a thermoplastic composite laminated structure with a reinforcing layer, a shielding layer, and a thermal protection layer, where these layers are consolidated using a thermoplastic resin to provide structural rigidity, thermal protection, and electromagnetic shielding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If metal structural components are used for battery enclosures, then structural support strength is improved, but weight increases significantly

Engineering Contradiction:

Improvestructural support strengthVSAvoidenclosure weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent applies composite materials by combining thermoplastic resin with reinforcing fibers (such as carbon fibers, glass fibers, or aramid fibers) to create a composite structure that provides both structural support and weight reduction. The composite material achieves high strength-to-weight ratio, maintaining structural integrity while significantly reducing enclosure weight compared to solid metal components.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent segments the enclosure structure into multiple functional layers including a thermoplastic resin matrix layer and reinforcing fiber layers. This segmentation allows each layer to perform its specific function optimally - the thermoplastic resin provides toughness and thermal resistance, while the reinforcing fibers provide structural strength, achieving weight reduction without compromising structural support.

Inventive Principle:

Principle #1Segmentation

2Strength

If metal enclosures are used, then structural support is provided, but thermal insulation and fire resistance are insufficient

Engineering Contradiction:

Improvestructural supportVSAvoidthermal runaway propagation

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent applies local quality by selecting thermoplastic resin materials with specific fire-resistant properties and thermal insulation characteristics for the enclosure structure. The thermoplastic resin composition is specifically designed to resist thermal runaway propagation and provide thermal insulation, creating localized fire resistance and thermal protection in critical areas of the battery enclosure.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent converts the potential harm of thermal runaway by using thermoplastic resin materials that are designed to resist and contain thermal propagation. The material properties of the thermoplastic resin are specifically selected to prevent fire spread and thermal damage, transforming a potential weakness into a protective feature that enhances battery safety.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Strength

If metal enclosures are used, then structural support is achieved, but electromagnetic shielding is inadequate

Engineering Contradiction:

Improvestructural supportVSAvoidelectromagnetic interference

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent applies composite materials by incorporating conductive fibers or metal-coated fibers into the thermoplastic resin matrix. This composite structure provides electromagnetic shielding capability while maintaining the lightweight advantage. The conductive elements within the composite material create a shielding effect against electromagnetic interference without requiring solid metal enclosures.

Inventive Principle:

Principle #40Composite materials

4Device complexity

If multi-functional layers are consolidated into one structure, then device complexity is reduced, but manufacturing precision requirements increase

Engineering Contradiction:

Improvestructure complexityVSAvoidconsolidation precision

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent merges multiple functional layers (thermoplastic resin matrix, reinforcing fibers, and potentially conductive layers) into a single integrated composite structure. This consolidation reduces the number of separate components and assembly steps, simplifying the overall device complexity. The multi-functional layers are combined during the molding process to create a unified structure that provides structural support, thermal resistance, and electromagnetic shielding simultaneously.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS20250118842A1Battery enclosure including multi-functional, multi-layered thermoplastic composite laminated structure

Publication Date: 2025.04.10 SEKISUI AEROSPACE INC

AI summary

A battery enclosure for a battery system includes a reinforcing layer including reinforcing fibers, a shielding layer, and a thermal protection layer. At least one of the reinforcing fibers, the shielding layer, and the thermal protection layer is consolidated using a thermoplastic resin into one of a body and a cover of the battery enclosure. The shielding layer is arranged on one side of the one of the body and the cover and the thermal protection layer is arranged on opposite side of the one of the body and the cover.