Foamed Plastic Battery Housing for Electric Vehicle Energy Absorption
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Solution Overview
Problem
Existing electric battery housings for motor vehicles and movable units are inefficient in terms of economic and structural effort, lack effective mechanical energy absorption, and provide inadequate thermal insulation and safety against thermal runaway and mechanical impacts.
Innovation Solution
The battery housing is made of expanded or foamed plastic, allowing for higher mechanical energy absorption, simplified assembly, and enhanced thermal insulation, with features like a high gas content for lightweight construction and flame retardancy, and the ability to absorb and release pressure safely.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional battery housing materials are used, then structural strength is maintained, but mechanical energy absorption capability is insufficient
Solution Approach 1:
The patent changes the material parameters by using foamed plastic with specific density ranges (0.05-0.3 g/cm³) and foam cell structures, transforming the housing from rigid to energy-absorbing while maintaining safety through controlled deformation characteristics
Solution Approach 2:
The patent employs composite construction by combining foamed plastic material with appropriate structural design elements, creating a housing that integrates both mechanical energy absorption and thermal safety functions in a unified structure
2Ease of manufacture
If conventional battery housing design is used, then assembly is complex, but production automation is limited
Solution Approach 1:
The patent divides the battery housing into modular segments that can be independently manufactured and then assembled, enabling both simplified assembly procedures and compatibility with automated manufacturing systems
Solution Approach 2:
The housing design integrates multiple functions (protection, insulation, structural support) into a single component, reducing the number of parts and assembly steps while maintaining manufacturability through standard processes
3Temperature
If dense battery housing material is used, then mechanical strength is high, but thermal insulation performance is reduced
Solution Approach 1:
The patent optimizes the foam density parameter within specific ranges (0.05-0.3 g/cm³) to achieve the optimal balance between mechanical strength and thermal insulation, where the cellular structure provides both cushioning and heat barrier properties
Solution Approach 2:
The patent utilizes the porous cellular structure of foamed plastic to provide thermal insulation through air trapping in closed cells, while the foam matrix maintains mechanical integrity for impact resistance
4Reliability
If solid battery housing construction is used, then structural integrity is maintained, but pressure release capability is limited
Solution Approach 1:
The patent modifies the structural parameters by incorporating controlled void spaces and deformation zones within the foamed plastic housing, allowing progressive collapse and pressure release pathways while maintaining overall structural integrity through the foam matrix
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 design significantly reduces economic effort, enhances safety through pressure release and thermal insulation, and provides high resistance to impacts and vibrations, enabling automated production and flexible installation.
Implementation Method 1
the battery housing, compared to battery housings of this type that are known from the prior art, is suitable to absorb significantly higher mechanical energy amounts
Implementation Method 2
The material properties of the expanded or foamed plastic, ensure a thermal insulation of the electric battery in particular in cold environments
Implementation Method 3
In the event of a so-called thermal runaway, the electric battery designed according to the invention ensures a high safety due to the slight resistance of the battery housing. Possible pressure build-up can be released directly into the environment
Data Source
AI summary
The invention relates to an electric battery (1) for a motor vehicle which is electrically or partly electrically driven or a movable or stationary unit, having a battery housing (5) and a plurality of battery cells (2) arranged therein. The aim of the invention is to allow such an electric battery (1) to be produced with minimal costs and technical structural complexity while still having a high degree of operational reliability. This is achieved in that the battery housing (5) is made of an expanded or foamed plastic.