Metal-Composite Laminate Structure for Lightweight Battery Heat Shielding
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Solution Overview
Problem
Existing composite materials used in electric vehicles, such as carbon fiber-reinforced plastics, are lightweight but have limited shape stability and are prone to corrosion, while metal materials are heavy and corrosive, posing risks due to heat generation from battery packs.
Innovation Solution
A composite laminate comprising a unidirectional tape layer with thermoplastic resin and continuous fibers, and a metal layer, with specific fiber and resin content ranges, to enhance stability and flame resistance, including an adhesive layer for bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If metal materials such as steel and aluminum are used, then stability against heat is improved, but weight increases and corrosion resistance deteriorates
Solution Approach 1:
The patent uses a composite laminate structure combining metal layers (for heat stability) with unidirectional tape layers containing thermoplastic resin and continuous fibers (for weight reduction). This composite approach allows the metal component to provide thermal stability while the polymer matrix and fibers reduce overall weight compared to solid metal construction.
2Temperature
If metal materials such as steel and aluminum are used, then stability against heat is improved, but corrosion resistance deteriorates
Solution Approach 1:
The metal layer is combined with a unidirectional tape layer containing thermoplastic resin and continuous fibers, creating a composite structure where the polymer matrix provides corrosion resistance while the metal layer maintains heat stability. The composite structure protects the metal from direct environmental exposure.
3Weight of moving object
If composite materials such as carbon fiber-reinforced plastic are used, then weight is reduced and corrosion resistance is improved, but shape stability deteriorates due to low elongation
Solution Approach 1:
The patent employs a unidirectional tape layer with continuous fibers (40-70 wt%) that provides localized reinforcement in specific directions. This allows the composite to achieve both weight reduction and improved shape stability by orienting fibers to resist deformation in critical directions while maintaining overall lightweight characteristics.
4Weight of moving object
If composite materials such as carbon fiber-reinforced plastic are used, then weight is reduced and corrosion resistance is improved, but shape stability deteriorates
Solution Approach 1:
The unidirectional tape layer with continuous fibers provides localized reinforcement where needed, allowing the composite to achieve both weight reduction and improved shape stability by orienting fibers to resist deformation in critical directions while maintaining overall lightweight characteristics.
5Weight of moving object
If battery pack weight is reduced, then fuel efficiency is improved, but thermal runaway risk increases due to heat generation from secondary batteries
Solution Approach 1:
The composite laminate combines metal layers (steel or aluminum) which provide heat resistance and structural stability, with unidirectional tape layers containing flame retardant thermoplastic resin and continuous fibers. This structure enables weight reduction while maintaining thermal stability to prevent heat propagation from battery cells.
Solution Approach 2:
The unidirectional tape layer acts as an intermediary barrier between battery cells, providing both mechanical support and thermal management. The flame retardant thermoplastic resin and continuous fibers in the tape layer serve as a protective interface that can withstand heat generation while maintaining structural integrity.
Data Source
AI summary
A composite laminate according to embodiments of the present disclosure includes a unidirectional tape layer including a thermoplastic resin and continuous fibers, and a first metal layer formed on the unidirectional tape layer. A content of the continuous fibers is 40 wt % or more based on the total weight of the unidirectional tape layer. The flame resistance and lightness of the composite laminate may be improved.