Flexible Composite Battery Cover for Thermal Insulation

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Solution Overview

Problem

Rigid plastic battery covers are heavy, inflexible, and ineffective at thermal insulation, leading to reduced battery life and increased shipping and storage costs.

Innovation Solution

A flexible, one-piece insulative battery cover with a composite structure comprising a reflective outermost thermoplastic layer, a metal layer, and a nonwoven intermediate layer, bonded via ultrasonic welds, which is lightweight, foldable, and provides effective thermal protection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If rigid plastic covers are used to protect batteries, then mechanical protection is provided, but thermal insulation is insufficient and weight is excessive

Engineering Contradiction:

Improvethermal insulationVSAvoidcover weight

Core Design Contradiction:

TemperatureVSWeight of moving object

Solution Approach 1:

The battery cover uses a composite structure combining multiple materials: an outer rigid plastic layer for mechanical protection, a middle layer of thermal insulation material (such as foam or air pockets) for thermal protection, and an inner flexible layer for conformal fit. This composite approach allows the cover to achieve both mechanical strength and thermal insulation without excessive weight.

Inventive Principle:

Principle #40Composite materials

2Ease of operation

If rigid plastic covers are used, then structural strength is maintained, but flexibility and ease of handling are reduced

Engineering Contradiction:

Improveflexibility and handlingVSAvoidstructural strength

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The battery cover is divided into multiple functional layers: an outer rigid shell for structural strength, a middle insulating layer for thermal protection, and an inner flexible lining for ease of installation and conformal fit. This segmentation allows each layer to perform its specific function optimally while working together as a unified cover system.

Inventive Principle:

Principle #1Segmentation

3Reliability

If rigid plastic battery covers are used, then protection is provided, but storage space and shipping costs increase due to bulkiness

Engineering Contradiction:

Improvebattery protectionVSAvoidstorage volume

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The battery cover employs a thin-walled composite structure that maintains adequate structural strength and thermal insulation through material composition rather than thickness. The use of flexible materials allows the cover to conform closely to the battery shape, minimizing air gaps and reducing overall volume for storage and shipping while maintaining protective functions.

Inventive Principle:

Principle #30Flexible shells and thin films

4Ease of manufacture

If rigid plastic covers are used, then manufacturing simplicity is maintained, but thermal degradation protection is insufficient

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidthermal degradation

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The cover integrates multiple materials with complementary properties: the outer rigid plastic layer provides mechanical protection and is easy to manufacture using conventional molding; the middle layer incorporates thermal insulation materials (such as closed-cell foam or air-trapping structures) that resist thermal degradation; and the inner layer ensures conformal contact with the battery. This composite construction maintains manufacturing feasibility while adding essential thermal protection.

Inventive Principle:

Principle #40Composite materials

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 flexible battery cover maintains battery acid temperature within a recommended range, extends battery life, reduces manufacturing costs, and facilitates easy handling and storage.

Implementation Method 1

a reflective outermost thermoplastic layer

Methodology Applied

Scientific EffectThermal radiation reflection: Reflection

Implementation Method 2

a metal layer sandwiched between the reflective outermost thermoplastic layer and the second thermoplastic innermost layer

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

a nonwoven intermediate layer sandwiched between the composite outermost layer and the first thermoplastic innermost layer

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 4

bonded via ultrasonic welds

Methodology Applied

Scientific EffectUltrasonic welding: Ultrasonic Vibration

Data Source

PatentEP3707761B1Battery cover and method of construction thereof

Publication Date: 2024.02.21 FEDERAL MOGUL POWERTRAIN INC

Figure 1~2
Figure 3~5

AI summary

A flexible, insulative battery cover and method of construction thereof are provided. The batter cover includes a flexible, tubular wall circumferentially bounding a cavity extending between a bottom end and a top end. The flexible, tubular wall has a composite outermost layer, a first thermoplastic innermost layer, and a nonwoven intermediate layer. The nonwoven intermediate layer is sandwiched between the composite outermost layer and the first thermoplastic innermost layer. The composite outermost layer includes a reflective outermost thermoplastic layer, a second thermoplastic innermost layer and a metal layer sandwiched between the reflective outermost thermoplastic layer and the second thermoplastic innermost layer.