Multilayered Power Cell Housing with Metal Cover
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Solution Overview
Problem
Conventional housings for electrical power cells in motor vehicles are lightweight and electrically insulating but lack mechanical strength and are flammable, failing to provide adequate protection against mechanical damage and electromagnetic radiation.
Innovation Solution
A multilayered housing composed of a thermoplastic polymer support layer and a metal cover layer, which can be arranged on the outer or inner side, offering enhanced mechanical strength and fire resistance, with the option of additional intermediate layers for improved adhesion and using recycled materials to enhance cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional plastic housings (polyethylene or polypropylene) are used, then the housing is lightweight and electrically insulating, but the mechanical strength is poor and the housing is flammable at high temperatures
Solution Approach 1:
The housing is constructed as a composite structure with an inner plastic housing made of polyethylene or polypropylene and an outer metal housing made of aluminum or aluminum alloy. This composite design combines the advantages of both materials: the plastic provides lightweight properties and electrical insulation, while the metal provides enhanced mechanical strength and fire resistance. The two housing layers are connected through connection elements that integrate both materials, achieving a synergistic effect that resolves the contradiction between lightweight requirements and mechanical strength requirements.
2Weight of moving object
If conventional plastic housings (polyethylene or polypropylene) are used, then the housing is lightweight, but the housing is flammable at high temperatures or in case of fire
Solution Approach 1:
The composite housing structure with inner plastic and outer metal layers provides both lightweight properties and fire resistance. The metal outer housing acts as a fire barrier that prevents flame propagation and protects the plastic inner housing from direct fire exposure.
3Ease of manufacture
If conventional plastic housings are used, then the housing is easy to manufacture, but protection against electromagnetic radiation is insufficient
Solution Approach 1:
The metal outer housing provides electromagnetic shielding that blocks electromagnetic radiation from reaching the electrical power cells inside the housing. The conductive metal layer creates a Faraday cage effect that attenuates electromagnetic fields, while the plastic inner housing maintains manufacturing simplicity through injection molding techniques.
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 multilayered housing provides improved stiffness and mechanical strength, protecting electrical power cells from mechanical damage and fire, while maintaining lightweight properties and surface quality, and offering protection against electromagnetic radiation.
Implementation Method 1
a multilayered material comprising at least one support layer of thermoplastic polymer and at least one cover layer of metal adhering to each other
Data Source
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AI summary
A housing suitable to comprise multiple electrical power cells in electrically driven motor vehicles comprises at least one lower receiving part and one upper covering part. Both parts fit together and create inside a hollow space. Both parts are prepared from a multilayered material comprising at least one support layer of thermoplastic polymer and at least one cover layer of metal adhering to each other. Such housing is perfectly suitable to protect the power cells inside against mechanical damage and against the influence of fire and/or electromagnetic radiation.