Sandwich Battery Housing Structure Without Potting Compounds
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Solution Overview
Problem
New-generation batteries with the 'cell-to-pack' design face challenges in potting compound application, leading to mechanical and thermal performance issues, complex recycling processes, and poor recyclability, especially in plastic or fiber-reinforced plastic casings.
Innovation Solution
A battery housing design featuring a sandwich-like structure with a battery component holder between two housing components, connected via bonding, welding, or interlocking mechanisms, eliminating the need for potting compounds and enhancing torsional and flexural stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If potting compound is used to bond battery cells to the housing, then electrical and thermal insulation is achieved, but the recycling process becomes complex and difficult
Solution Approach 1:
The patent removes the potting compound from the battery housing design entirely. Instead of using potting compound to bond and insulate battery cells, the invention uses a modular battery component holder that can be directly attached to the housing through mechanical means such as clips or snap-fit connections. This extraction of the potting compound eliminates the recycling complexity while maintaining the necessary electrical and thermal insulation through alternative design approaches.
Solution Approach 2:
The patent segments the battery housing into distinct modular components: the housing itself, the battery component holder, and the battery cells. This segmentation allows each component to be independently manufactured, assembled, and recycled. The battery component holder serves as an intermediate structure that provides both mechanical support and insulation, replacing the need for potting compound while enabling easier disassembly and recycling.
2Strength
If potting compound is used to fill the battery housing, then mechanical rigidity is improved, but the process becomes slow and difficult to control
Solution Approach 1:
The patent replaces the chemical-based potting compound system with a mechanical assembly system. Instead of relying on slow-curing potting compound to provide structural rigidity, the invention uses mechanically assembled components (battery component holder with clips or snap-fit connections) that provide immediate structural support and rigidity upon assembly, dramatically improving production speed and process control.
3Ease of manufacture
If plastic or fiber-reinforced plastic is used for the battery housing, then manufacturing flexibility is improved, but adhesion and recyclability deteriorate
Solution Approach 1:
The patent introduces the battery component holder as an intermediary component between the plastic housing and the battery cells. This intermediary provides a standardized interface for mechanical attachment (through clips or snap-fit connections) that works reliably with plastic housings without requiring complex surface pretreatment for adhesion. The intermediary component simplifies the connection process and maintains recyclability by enabling clean separation of components.
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 design improves recyclability, mechanical strength, and thermal/electrical insulation while simplifying the recycling process and maintaining structural integrity.
Implementation Method 1
the battery component holder is materially bonded to the first battery housing component and/or to the second battery housing component
Implementation Method 2
connected via bonding, welding, or interlocking mechanisms
Implementation Method 3
A battery housing design featuring a sandwich-like structure with a battery component holder between two housing components, connected via bonding, welding, or interlocking mechanisms, eliminating the need for potting compounds and enhancing torsional and flexural stiffness
Implementation Method 4
the battery housing provides improved electrical and thermal insulation between the battery components
Implementation Method 5
the battery housing provides improved electrical and thermal insulation between the battery components
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a battery housing (1) for receiving a plurality of battery components (3), comprising a first battery housing component (10), a second battery housing component (20), and at least one battery component holder (30) having a plurality of receiving devices (40) for receiving the battery components (3). The battery component holder (30) is arranged sandwich-like between the first battery housing component (10) and the second battery housing component (20) and is metallurgically connected to the first battery housing component (10) and/or to the second battery housing component (20). The invention further relates to a battery (4) comprising a battery housing (1) and to a motor vehicle comprising a battery (4).