Insulated Battery Box Assembly for Off-Road Heat and Moisture Protection

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Solution Overview

Problem

Traditional side-by-side vehicles equipped with internal combustion engines face challenges in accommodating electric motors and rechargeable batteries due to different operational, installation, accessibility, safety, heat management, and weight distribution requirements.

Innovation Solution

A battery box assembly with a metallic skeleton, insulative inner and outer layers, and specific compartmentalization for battery modules and electrical components, providing protection against harsh environments, improved accessibility, and effective heat management, allowing standard components to be used while ensuring safety and efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If batteries and electrical components are installed in traditional side-by-side vehicles, then electric propulsion is achieved, but protection against harsh environments (moisture, dirt) is insufficient

Engineering Contradiction:

Improveprotection against harsh environmentsVSAvoidbattery box assembly structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The battery box assembly is divided into multiple compartments separated by inner walls, with each compartment housing specific battery modules or electrical components. This segmentation allows independent protection and management of different components while maintaining overall environmental protection.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The battery box employs a composite structure combining metallic skeleton for structural strength, insulative inner layer for thermal and electrical insulation, and insulative outer layer for additional environmental protection. This multi-material approach provides comprehensive protection against harsh environments.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If standard rated components are used in battery assemblies, then cost is reduced, but protection against harsh environments requires additional components

Engineering Contradiction:

Improveuse of standard componentsVSAvoidmoisture and dirt impact

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The insulative inner and outer layers act as intermediary protective barriers between the standard-rated electrical components and the harsh external environment. These layers provide thermal, electrical, and environmental protection without requiring the components themselves to be specially rated for harsh conditions.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of operation

If batteries are positioned for improved accessibility, then maintenance is easier, but weight distribution and heat management become challenging

Engineering Contradiction:

Improveaccessibility of batteriesVSAvoidheat management

Core Design Contradiction:

Ease of operationVSTemperature

Solution Approach 1:

The battery box incorporates localized thermal management features including insulative layers in specific areas, ventilation pathways designed for heat dissipation, and compartmentalization that allows targeted cooling or heating of battery modules based on their operational heat generation patterns.

Inventive Principle:

Principle #3Local quality

4Reliability

If inner walls separate battery cavities from component cavity, then safety is improved, but airflow between cavities is restricted

Engineering Contradiction:

Improvesafety isolationVSAvoidairflow restriction

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The second inner wall acts as a flexible barrier that provides safety isolation between battery cavities and component cavity while allowing controlled thermal energy transfer. The wall's design permits selective airflow restriction for safety while maintaining thermal management through conduction and controlled pathways.

Inventive Principle:

Principle #30Flexible shells and thin films

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 box assembly effectively protects batteries and electrical components from harsh conditions, enables efficient installation and operation, and provides improved safety and heat management, reducing the need for individually rated components and enhancing the overall performance of electric off-road vehicles.

Implementation Method 1

an insulative inner layer coupled with the metallic skeleton. The insulative inner layer faces an inner space defined by the metallic skeleton... an insulative outer layer coupled with the metallic skeleton. The insulative outer layer facing outwardly from the metallic skeleton

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS20240313315A1Battery box assembly

Publication Date: 2024.09.19 TEXTRON INC

AI summary

An improved technique is directed to a battery box assembly. The technique includes a metallic skeleton. The technique further includes an insulative inner layer coupled with the metallic skeleton. The insulative inner layer faces an inner space defined by the metallic skeleton. The technique further includes an insulative outer layer coupled with the metallic skeleton. The insulative outer layer facing outwardly from the metallic skeleton.