Foam Shell Battery Assembly Impact Absorption

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Solution Overview

Problem

Conventional battery assemblies for electrified vehicles lack effective impact energy absorption and thermal insulation, which are crucial for protecting high voltage battery arrays from external impacts and temperature variations.

Innovation Solution

A battery assembly that incorporates a foam shell made of materials like polypropylene or polyethylene surrounding the battery array, with a barrier secured to the foam shell, providing impact energy absorption and thermal insulation. The foam shell can be a two-piece design with a cover and tray, and the barrier is made of materials such as polyamide or polypropylene, featuring straps for secure mounting to the vehicle body and ribbing for reinforcement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional sheet metal structures are used to surround battery arrays, then structural strength is provided, but impact energy absorption and thermal insulation are insufficient

Engineering Contradiction:

Improvestructural strengthVSAvoidimpact energy absorption and thermal insulation

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent employs composite materials by combining foam core layers with skin layers (thermoplastic or metal) to create a shell structure that simultaneously provides impact energy absorption, thermal insulation, and structural strength. The foam material absorbs impact energy while the skin provides structural integrity, resolving the contradiction between strength and protection against harmful factors.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent utilizes foam materials with porous structures to provide both impact energy absorption and thermal insulation properties. The porous foam core absorbs impact forces through deformation while also providing thermal insulation barriers, addressing the insufficient protection against harmful factors while maintaining structural requirements.

Inventive Principle:

Principle #31Porous materials

2Object-affected harmful factors

If foam shell and barrier are added around battery array, then impact energy absorption and thermal insulation are improved, but device complexity increases

Engineering Contradiction:

Improveimpact energy absorption and thermal insulationVSAvoiddevice complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent merges multiple protective functions into integrated components. The shell structure combines impact absorption, thermal insulation, and structural support functions in a single assembly. The barrier is integrated with the shell to provide both mechanical protection and thermal insulation, reducing overall device complexity while maintaining enhanced protection against harmful factors.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The foam shell and barrier components serve multiple functions simultaneously: structural support, impact energy absorption, thermal insulation, and protection against environmental factors. This multi-functionality reduces the need for separate components, thereby managing device complexity while providing comprehensive protection.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Strength

If barrier with straps and ribbing is used, then structural reinforcement and secure mounting are achieved, but manufacturing complexity increases

Engineering Contradiction:

Improvestructural reinforcementVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The barrier is segmented into modular components with standardized features such as straps and ribbing that can be manufactured separately and assembled. This segmentation allows for specialized manufacturing of each component while maintaining overall structural reinforcement, balancing manufacturing complexity with strength requirements.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The barrier design incorporates variable parameters such as strap positioning, ribbing patterns, and material properties that can be adjusted based on specific application requirements. This flexibility allows optimization of manufacturing processes while maintaining the necessary structural reinforcement and secure mounting capabilities.

Inventive Principle:

Principle #35Parameter changes

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 offers enhanced impact energy absorption and thermal insulation, ensuring the safety and efficiency of the battery assembly by distributing impact forces and regulating temperature, thereby protecting the battery cells and electronic components.

Implementation Method 1

The foam shell and barrier are configured to absorb impact energy

Methodology Applied

Scientific EffectImpact energy absorption: Damping

Implementation Method 2

The foam shell and barrier are configured to absorb impact energy and thermally insulate the battery array from external temperatures

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS11264667B2Battery assembly including structural foamed materials

Publication Date: 2022.03.01 FORD GLOBAL TECH LLC

AI summary

A battery assembly includes a battery array and a foam shell that surrounds the battery array. The battery array may be housed within a foam shell, and a barrier can be secured to the foam shell to establish a battery assembly. The battery assembly may then be secured to a vehicle body.