Fiber Composite Battery Pack Case for Lightweight Impact Protection
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Solution Overview
Problem
Electric vehicle battery packs face challenges in reducing weight while maintaining sufficient rigidity to protect battery modules from external impacts, which affects energy efficiency and overall vehicle performance.
Innovation Solution
An electric vehicle battery pack case incorporating a combination of continuous and discontinuous fibers, with a flame retardant coating, to achieve lightweight protection and enhanced safety through a specific fiber ratio and resin composition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the battery pack case uses traditional solid materials to ensure rigidity and protection, then the protective function is improved, but the weight increases significantly
Solution Approach 1:
The patent applies composite materials by combining continuous fibers (30-70 wt%) and discontinuous fibers (20-50 wt%) within a resin matrix to create a case structure that achieves high strength-to-weight ratio. The continuous fibers provide structural rigidity while the discontinuous fibers add impact resistance, enabling the case to protect battery modules effectively without excessive weight gain.
Solution Approach 2:
The patent implements local quality by strategically positioning continuous fibers in regions requiring high structural strength and discontinuous fibers in areas needing impact absorption. This spatial differentiation of fiber types allows each region of the case to have optimized properties for its specific functional requirements, maximizing protection while minimizing overall weight.
2Weight of moving object
If the battery pack case reduces material density to lower weight, then weight reduction is achieved, but the rigidity and impact resistance deteriorate
Solution Approach 1:
The patent uses composite materials with a specific fiber combination where continuous fibers (30-70 wt%) maintain structural integrity and discontinuous fibers (20-50 wt%) provide impact resistance. This composite structure enables the case to achieve both weight reduction and enhanced impact protection, as the fiber-reinforced resin matrix offers superior strength-to-weight characteristics compared to traditional solid materials.
Solution Approach 2:
The patent applies parameter changes by optimizing the weight percentage ratios of continuous fibers, discontinuous fibers, and resin matrix. By adjusting these compositional parameters within specific ranges, the case achieves the optimal balance between weight reduction and impact resistance, demonstrating how material composition parameters can be tuned to meet conflicting performance requirements.
3Strength
If the battery pack case uses high-strength solid materials to protect against external impact, then the protective function is improved, but the energy efficiency and fuel economy deteriorate
Solution Approach 1:
The patent employs composite materials with continuous and discontinuous fibers in a resin matrix to create a lightweight yet highly protective case structure. This composite construction provides the necessary impact protection while minimizing weight, thereby improving energy efficiency and fuel economy without compromising safety.
Solution Approach 2:
The patent implements parameter changes by optimizing the weight percentages of continuous fibers (30-70 wt%), discontinuous fibers (20-50 wt%), and resin matrix. This optimization enables the case to achieve adequate impact protection with reduced weight, directly improving the vehicle's energy efficiency and fuel consumption characteristics.
Data Source
AI summary
The present invention relates to an electric vehicle battery pack case, and the purpose of the present invention is to provide an electric vehicle battery pack case which comprises continuous fibers and discontinuous fibers, and thus is lightweight and yet has rigidity.