Double-Walled Battery Housing Element for Crash and Thermal Protection
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Solution Overview
Problem
The production of large energy store housings for electric vehicles faces challenges such as weight constraints, limited manufacturing methods, and high requirements for crash behavior, corrosion protection, and thermal management due to their size and exposed installation situation.
Innovation Solution
A double-walled housing element with an outer aluminum sheet and an inner reinforcing steel sheet, where the steel sheet provides mechanical reinforcement and thermal protection, and is coated for corrosion resistance, allowing for efficient production and optimal mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a large energy store housing is produced to meet demanded ranges, then the energy storage capacity is improved, but the weight increases
Solution Approach 1:
The housing element uses a composite structure combining aluminum sheet (outer wall) and steel reinforcing element (inner wall). The aluminum provides lightweight corrosion-resistant properties while the steel adds mechanical strength, achieving optimal weight-to-strength ratio for large energy store housings
Solution Approach 2:
The reinforcing element is selectively positioned in specific regions of the housing element where mechanical strength is most needed, such as areas subject to crash loads or thermal events, rather than uniformly reinforcing the entire housing structure
2Strength
If the housing is reinforced to meet crash behavior requirements, then the mechanical strength is improved, but the weight increases
Solution Approach 1:
The combination of aluminum and steel materials provides high mechanical strength with optimized weight. The steel reinforcing element contributes high tensile strength and toughness while the aluminum keeps the overall weight low
Solution Approach 2:
Reinforcement is applied locally in specific regions rather than throughout the entire housing, placing steel strengthening elements where crash loads and mechanical stresses are most likely to occur
3Object-affected harmful factors
If thermal protection is enhanced to withstand thermal events, then the thermal resistance is improved, but the device complexity increases
Solution Approach 1:
The steel reinforcing element provides inherent thermal protection as steel has higher melting point and thermal stability compared to aluminum. This composite material approach provides thermal resistance without adding complex thermal management systems
Solution Approach 2:
The double-walled structure with outer aluminum wall and inner steel reinforcing element creates a thermal barrier that protects against thermal events, with the steel acting as an intermediary protective layer
4Reliability
If corrosion protection is improved for exposed installation, then the durability is improved, but the manufacturing cost increases
Solution Approach 1:
The aluminum outer wall provides inherent corrosion resistance without requiring additional corrosion protection treatments. Aluminum naturally forms a protective oxide layer that resists corrosion, eliminating the need for complex corrosion protection systems
Solution Approach 2:
The aluminum material is selected for its natural corrosion-resistant properties, providing durable protection for the housing element in exposed installation conditions without requiring additional protective coatings or treatments
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 achieves a balance of low weight, high mechanical strength, and effective thermal protection, enabling the housing element to withstand extreme conditions while being cost-effective and efficient to manufacture.
Implementation Method 1
The steel sheet advantageously enables selective and permanent reinforcement of the housing element. In the event of a short circuit inside a high-voltage store, temperatures of up to 1000° C. and more can arise, which would cause aluminum to melt. The steel sheet advantageously enables very good thermal protection if there is a thermal event
Implementation Method 2
the reinforcing element is provided with an anti-corrosion layer on one side or both sides. A steel sheet is preferably CDC- or PVC-coated (CDC—cathodic dip coat, PVC—polyvinyl chloride)
Data Source
AI summary
A housing element for an energy store housing has a placement or arrangement area designed to arrange a multiplicity of energy storage cells thereon, the housing element being double-walled in the arrangement area, that is it has an outer wall and an inner wall. The outer wall is formed by a lightweight metal sheet, in particular an aluminum sheet, and the inner wall is formed by a reinforcement element that is arranged on the outer wall.