Fiber-Reinforced Polyamide Battery Box for Heat and Shock Resistance
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Solution Overview
Problem
Conventional metal battery boxes for electric and hybrid vehicles are heavy, prone to deterioration in humid environments, and fail to adequately protect batteries from extreme temperatures and shocks, while also lacking in flame retardancy and flexibility in design.
Innovation Solution
A battery box composed of a polyamide matrix with a high number of carbon atoms per nitrogen atom, reinforced with fibers and incorporating flame retardants, providing lightweight protection against environmental stresses and ensuring safety through improved thermal resistance and flammability criteria.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal case is used to protect the battery, then protection against environmental stresses is improved, but weight increases and the case deteriorates quickly in humid environments
Solution Approach 1:
The patent employs composite materials consisting of polyamide matrix combined with reinforcing fibers (glass, carbon, or aramid) to create a battery case that is both lightweight and mechanically strong. This composite structure provides the necessary protection against environmental stresses while significantly reducing weight compared to traditional metal cases. The polyamide matrix offers inherent corrosion resistance to humid environments, while the fiber reinforcement provides structural integrity and impact resistance.
2Reliability
If a metal case is used to protect the battery, then protection against environmental stresses is improved, but the case deteriorates quickly over time in humid environments
Solution Approach 1:
The composite material system of polyamide matrix with fiber reinforcement provides superior long-term durability in humid environments. The polyamide matrix is inherently resistant to corrosion and degradation from moisture, unlike metal cases that rust and deteriorate. The fiber reinforcement maintains structural stability over time, preventing the case from becoming brittle or deforming. This combination ensures the battery case maintains its protective function throughout the entire service life of the battery pack.
Solution Approach 2:
The patent modifies the material parameters by selecting polyamides with specific molecular weight ranges and incorporating fiber reinforcements with appropriate aspect ratios and surface treatments. These parameter changes enhance the material's resistance to environmental degradation, UV radiation, and thermal cycling, thereby extending the service life of the battery case in harsh operating conditions.
3Weight of moving object
If conventional polyamides are used for the battery box, then weight is reduced, but resistance to extreme temperatures and shocks is insufficient
Solution Approach 1:
The patent reinforces the polyamide matrix with high-strength fibers such as glass fibers, carbon fibers, or aramid fibers. These fibers provide exceptional tensile strength, impact resistance, and thermal stability. The fiber-reinforced composite structure maintains its mechanical properties across extreme temperature ranges and resists shock loads better than unreinforced polyamide, while still being significantly lighter than metal alternatives.
Solution Approach 2:
The patent applies fiber reinforcement selectively in regions of the battery case where stress concentration is expected, such as mounting points, corners, and areas subject to impact. This localized reinforcement optimizes the strength-to-weight ratio by concentrating material where it is most needed, rather than uniformly thickening the entire case structure.
4Weight of moving object
If conventional polyamides are used for the battery box, then weight is reduced, but flammability criteria are not met
Solution Approach 1:
The patent modifies the polyamide material by incorporating flame retardant additives and selecting polyamide types with inherently better fire resistance. The material composition is adjusted to achieve appropriate flame spread ratings and smoke development characteristics required for automotive battery applications, while maintaining the lightweight advantage of plastic over metal.
Data Source
AI summary
The invention relates to a battery compartment for an electric or hybrid vehicle, characterised in that it consists of a composition comprising: - 20 to 80 wt% of reinforcement fibres relative to the total weight of the composition; - 0 to 20 wt% of at least one impact modifier relative to the total weight of the composition; - 0 to 20 wt% of additives relative to the total weight of the composition; - the remainder being a matrix comprising: - mainly at least one polyamide and - at least one flame retardant.