Conductive Joint for Shielded Composite Battery Enclosures

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Solution Overview

Problem

The challenge in the development of electric vehicles is to create a lightweight and safe enclosure for battery packs that effectively shields against electromagnetic interference (EMI) while maintaining mechanical integrity and reducing weight, particularly in the transition from fossil fuel-based powertrains to sustainable energy sources.

Innovation Solution

A battery pack enclosure design featuring a first metal wall member, a second wall member with a fiber-reinforced plastic laminate and a metal mesh layer, and a conductive joint using an electrically conductive metal fastener and coupling member that forms a Faraday cage, ensuring electrical contact between the metal mesh layer, the fastener, and the coupling member to isolate batteries from EMI.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If a metal mesh layer is embedded in fiber-reinforced plastic laminate to form shielded composite walls, then electromagnetic shielding effectiveness is improved, but manufacturing complexity increases due to the need to integrate multiple layers and materials

Engineering Contradiction:

Improveelectromagnetic shielding effectivenessVSAvoidmanufacturing complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent embeds a metal mesh layer within fiber-reinforced plastic laminate to create a composite material that provides both structural integrity and electromagnetic shielding. The metal mesh is integrated between layers of the laminate, forming a multi-layer composite structure that combines the advantages of both materials.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The metal mesh layer is nested within the fiber-reinforced plastic laminate structure, with the mesh positioned between laminate layers. This nesting approach allows the shielding layer to be integrated within the composite structure without adding external complexity.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Strength

If conventional non-conductive fasteners are used to join metal walls to shielded composites, then mechanical coupling is achieved, but electrical continuity for Faraday cage formation is disrupted

Engineering Contradiction:

Improvemechanical coupling strengthVSAvoidelectrical continuity

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent introduces a conductive intermediary element (such as a conductive adhesive layer or conductive grommet) that mediates between the non-conductive fastener and the metal walls. This intermediary maintains mechanical coupling while providing the necessary electrical continuity to preserve Faraday cage integrity.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent changes the electrical conductivity parameter of the fastening system by incorporating conductive materials into the joining mechanism. This allows the fastener system to simultaneously provide both mechanical strength and electrical continuity.

Inventive Principle:

Principle #35Parameter changes

3Strength

If solid metal walls are used for battery pack enclosure, then structural strength and EMI shielding are maximized, but vehicle weight increases significantly

Engineering Contradiction:

Improvestructural strengthVSAvoidenclosure weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent replaces solid metal walls with composite walls consisting of fiber-reinforced plastic laminate with embedded metal mesh. This composite structure maintains structural strength and EMI shielding properties while significantly reducing the weight compared to solid metal construction.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies metal mesh only in specific locations within the composite structure where EMI shielding is needed, rather than using solid metal throughout. This localized application of conductive material provides necessary shielding while minimizing weight.

Inventive Principle:

Principle #3Local quality

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 effectively reduces weight, enhances safety by forming a Faraday cage around the batteries, and maintains mechanical integrity through the use of a conductive joint that provides both electrical and mechanical coupling, effectively shielding against electromagnetic interference.

Implementation Method 1

first metal wall member, the metal mesh layer, and the joint can form a Faraday cage around the plurality of batteries

Methodology Applied

Scientific EffectFaraday cage: Faraday Cage

Data Source

PatentUS20250007074A1Conductive joint between shielded composites and metal parts

Publication Date: 2025.01.02 ATIEVA INC(US)

AI summary

A battery pack may include a plurality of batteries and an enclosure surrounding the plurality of batteries. The enclosure includes: a first metal wall member, a second wall member, the second wall member including a fiber-reinforced plastic laminate and having a metal mesh layer within the fiber-reinforced plastic laminate. The battery pack may include a joint between the first metal wall member and the second wall member, wherein the joint includes: an electrically conductive metal fastener that mechanically couples the first metal wall member to the second wall member, and an electrically conductive coupling member in mechanical and electrical contact with the first metal wall member and with the metal mesh layer.