Expandable Polymer Foam Enclosure for Battery Pack Assembly

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Solution Overview

Problem

Conventional battery packs for electrified vehicles require numerous components and fasteners, leading to increased assembly time and complexity, while also lacking efficient thermal management and durability.

Innovation Solution

The use of an expandable polymer foam enclosure, made from materials like epoxy, polyurethane, or silicone, that encapsulates the battery array, electrical distribution system, and other components, reducing the need for fasteners and enhancing thermal management and durability by filling gaps and providing a rigid, durable structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional battery packs use numerous components and fasteners to house battery cells and electrical components, then structural integrity and component retention are improved, but assembly time and device complexity increase

Engineering Contradiction:

Improvestructural integrityVSAvoidassembly complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent combines multiple separate components (enclosure walls, fasteners, thermal management elements, electrical insulation components) into a single integrated expandable foam structure. The foam encapsulates battery cells, electrical components, and thermal management systems while providing structural support, eliminating the need for separate fasteners and multiple enclosure parts.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The expandable foam enclosure performs multiple functions simultaneously: it provides structural support, thermal insulation, electrical insulation, mechanical protection, and thermal management. This multi-functional approach replaces numerous specialized components with a single versatile material system.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Stability of the object's composition

If conventional battery packs use multiple separate components and fasteners, then component retention is improved, but assembly time increases

Engineering Contradiction:

Improvecomponent retentionVSAvoidassembly speed

Core Design Contradiction:

Stability of the object's compositionVSProductivity

Solution Approach 1:

The foam is applied in an unexpanded state to the battery pack components, allowing it to conform to the exact geometry and secure all components in their proper positions before expansion. This preliminary positioning ensures stable component retention while eliminating the need for sequential fastening operations.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The expandable foam self-secures components through its expansion process, which naturally locks battery cells, electrical components, and structural elements in place without requiring external fasteners or additional assembly steps for component retention.

Inventive Principle:

Principle #25Self-service

3Ease of manufacture

If conventional battery packs use traditional enclosure structures, then manufacturing simplicity is maintained, but thermal management efficiency and durability decrease

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidthermal management efficiency

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent uses composite foam structures that combine materials with different thermal properties to achieve both ease of manufacture and superior thermal management. The foam can be formulated with thermal conductive fillers or layered with heat exchanger components to optimize thermal performance while maintaining manufacturing simplicity.

Inventive Principle:

Principle #40Composite materials

4Strength

If conventional battery packs use multiple separate components, then structural durability is improved, but the number of parts and assembly complexity increase

Engineering Contradiction:

Improvestructural durabilityVSAvoidnumber of parts

Core Design Contradiction:

StrengthVSQuantity of substance

Solution Approach 1:

The patent merges multiple separate structural components into a single expandable foam enclosure that provides equivalent or superior structural durability. The foam monolithically supports battery cells, electrical components, and thermal management systems, reducing the total number of parts while maintaining structural integrity.

Inventive Principle:

Principle #5Merging (Combining)

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 simplifies the assembly process, reduces the number of parts required, improves thermal performance, increases energy absorption and durability, and provides internal and external fire protection, while maintaining component retention and stability.

Implementation Method 1

introducing an expandable polymer foam into the cavity. The expandable polymer foam expands and cures within the cavity to form an enclosure

Methodology Applied

Scientific EffectExpandable polymer foam expansion: Foam

Implementation Method 2

a thermal interface material is disposed between the battery array and the heat exchanger plate

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS20210119193A1Battery pack structures made of expandable polymer foams

Publication Date: 2021.04.22 FORD GLOBAL TECH LLC

AI summary

This disclosure details exemplary battery pack designs for use in electrified vehicles. An exemplary battery pack may include a battery system and an expandable polymer foam enclosure that substantially encapsulates the battery system. An expandable polymer foam may be introduced into a mold, expand, and then cure around to battery system to form the enclosure.