Composite EV Battery Housing for Impact Damping and Thermal Insulation
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Solution Overview
Problem
Existing electric battery housings for motor vehicles and movable units are inefficient in terms of structural and economic effort, lack effective mechanical energy absorption, and pose safety risks due to inadequate thermal insulation and pressure release in case of thermal runaway.
Innovation Solution
The battery housing is made from a material containing silicon, calcium, rubber, and/or silicone, allowing for higher mechanical energy absorption, simplified assembly, and enhanced thermal insulation, with features such as a multi-piece construction, fibre-reinforced adhesive tape for cell fixation, and integrated safety measures like flame retardancy and gas binding properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional battery housing materials are used, then the structure is simple and easy to manufacture, but the mechanical energy absorption capability is insufficient
Solution Approach 1:
The battery housing is made from a composite material containing silicon, calcium, rubber, and silicone components. This composite formulation provides superior mechanical energy absorption through the synergistic effects of the materials: silicon and calcium provide structural strength, while rubber and silicone provide elasticity and damping properties. The composite material achieves high mechanical energy absorption capability while maintaining manufacturability through established composite processing techniques.
Solution Approach 2:
The invention changes the material parameters by incorporating specific ratios of silicon, calcium, rubber, and silicone components. By adjusting the composition parameters and curing conditions of the composite material, the housing achieves optimized mechanical energy absorption properties. The material can be molded into complex shapes in a single process, maintaining ease of manufacture while achieving superior mechanical performance.
2Temperature
If conventional battery housing materials are used, then the production cost is low, but the thermal insulation performance is insufficient
Solution Approach 1:
The composite material system incorporates silicon-based compounds and rubber components that provide inherent thermal insulation properties. The calcium content contributes to thermal mass and insulation, while the rubber and silicone phases create a cellular structure that traps air pockets, enhancing thermal resistance. This composite approach achieves superior thermal insulation without requiring additional insulation layers or complex manufacturing processes.
3Reliability
If conventional battery housing materials are used, then the material is rigid and provides structural support, but it cannot effectively release pressure in case of thermal runaway
Solution Approach 1:
The battery housing incorporates flexible rubber and silicone components that allow the structure to deform under pressure. In case of thermal runaway, the housing can expand and rupture controlled weak points to release pressure safely. The flexible nature of the rubber-silicone matrix allows the housing to maintain structural integrity during normal operation while providing pressure relief pathways during abnormal conditions.
Solution Approach 2:
The composite material parameters are designed to exhibit different mechanical behaviors under different conditions. Under normal conditions, the cross-linked silicon-calcium-rubber-silicone matrix provides rigid structural support. Under extreme pressure conditions (thermal runaway), the material's compressibility and phase change characteristics allow controlled deformation and pressure release, achieving both structural support and safety functionality.
4Productivity
If traditional assembly methods are used, then the battery housing can be manufactured, but the assembly process is complex and time-consuming
Solution Approach 1:
The battery housing design merges multiple functions into a single component: the housing simultaneously provides structural support, thermal insulation, mechanical energy absorption, and electrical isolation. The composite material can be molded as a single piece or pre-assembled modules, eliminating the need for separate insulation layers, mounting brackets, and protective coatings. This integration dramatically simplifies the assembly process and increases productivity.
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
This solution significantly reduces economic effort, enhances mechanical resilience, ensures thermal insulation, and provides high safety by allowing pressure release and absorption of impacts, shocks, and vibrations, while enabling automated production and flexible installation.
Implementation Method 1
the battery housing, compared to battery housings of this type that are known from the prior art, is suitable to absorb significantly higher mechanical energy amounts
Implementation Method 2
the material properties of the material containing silicon and/or calcium and/or rubber and/or silicone, ensure a thermal insulation of the electric battery
Implementation Method 3
The material properties of the material containing silicon and/or calcium and/or rubber and/or silicone, ensure a thermal insulation of the electric battery in particular in cold environments
Implementation Method 4
In the event of a so-called thermal runaway, the electric battery designed according to the invention ensures a high safety due to the slight resistance of the battery housing. Possible pressure build-up can be released directly into the environment
Data Source
AI summary
An electric battery (1) for an electrically or partially electrically driven motor vehicle, movable or stationary unit has a battery housing (5) and a plurality of battery cells (2) arranged therein. According to the invention, the battery housing (5) is made from a material containing silicon and/or calcium and/or rubber and/or silicone to produce such an electric battery (1) with a minimum of economic and technical design effort while ensuring said battery is still highly operationally reliable.