Foldable Battery Cover Using Composite Material for Thermal Insulation
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Solution Overview
Problem
Battery life is reduced due to exposure to extreme high temperatures near motor vehicle engines or exhaust systems, which affects the efficiency and durability of automotive and marine batteries.
Innovation Solution
A flexible and foldable battery cover made from a single sheet of material with a thermoplastic polymer resin and polymer film, featuring a rectangular box shape with perforations that allows it to fold into a flattened shape for transportation and spring back into an open shape for installation, providing thermal insulation and easy installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a traditional rigid battery cover is used, then structural strength is maintained, but heat insulation performance deteriorates and transportation convenience is reduced
Solution Approach 1:
The battery cover uses a composite material comprising a thermoplastic polymer resin and a polymer film. This composite structure provides both thermal insulation properties to protect the battery from heat and sufficient structural strength to maintain cover functionality, resolving the contradiction between heat insulation and structural strength.
Solution Approach 2:
The battery cover incorporates a polymer film layer that provides flexibility while maintaining protective functions. This flexible structure allows the cover to conform to battery contours and provides thermal insulation without compromising structural integrity, addressing both heat protection and strength requirements.
2Ease of operation
If a rigid battery cover is used, then structural stability is maintained, but ease of transportation and storage deteriorates
Solution Approach 1:
The battery cover transitions from a rigid static structure to a flexible dynamic structure that can bend and fold. The polymer film allows the cover to be folded during transportation for compact storage, yet maintains sufficient structural stability when installed to protect the battery, resolving the contradiction between ease of transportation and structural stability.
3Ease of operation
If the battery cover is made foldable, then transportation convenience is improved, but manufacturing complexity increases
Solution Approach 1:
The battery cover is designed as a single continuous piece of composite material that can be folded along natural creases. This segmentation-free design avoids complex joints, hinges, or fasteners, maintaining manufacturing simplicity while enabling foldability for convenient transportation and storage.
4Temperature
If a thick battery cover is used, then thermal insulation is improved, but weight increases
Solution Approach 1:
The composite structure of thermoplastic polymer resin and polymer film provides effective thermal insulation with a thin profile. This lightweight composite material achieves the required thermal protection without adding significant weight, resolving the contradiction between thermal insulation performance and weight.
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 battery cover effectively reduces heat transfer to battery components, enhancing durability and efficiency while being cost-effective, lightweight, and aesthetically pleasing, with the ability to maintain its shape and unfold automatically when unrestrained.
Implementation Method 1
The material includes a layer of a thermoplastic polymer resin and a layer of polymer film... reduces the transfer of heat to battery components
Implementation Method 2
The battery cover has a thickness such that when the battery cover is unfolded, the material substantially maintains the rectangular box shape and when the battery cover is folded into the flattened shape, the material maintains a spring force such that, unless restrained, the battery cover would unfold to the rectangular box shape
Data Source
AI summary
Battery covers and methods for producing battery covers are described. One battery cover described herein includes a single sheet of material formed into a substantially rectangular box shape with an opening formed along one side, the rectangular box shape capable of being folded into a flattened shape for transportation and the material including a flexible laminate of at least one layer of synthetic fiber and a polymer film layer. The material has a thickness and other properties such that when the battery cover is unfolded, the material substantially maintains the rectangular box shape, and when the battery cover is folded into the flattened shape, the material maintains a spring force such that, unless restrained, the battery cover would unfold to the rectangular box shape.