SMC Battery Cover with Perforated Fire Coating
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Solution Overview
Problem
Existing battery cover structures made of poorly flammable plastics cannot withstand prolonged heat development, and current manufacturing methods for fire-protected battery box covers are labor-intensive.
Innovation Solution
A cover structure with an SMC base body and a fire protection coating, where the coating features a perforated design allowing the plastic matrix to pass through openings, forming a precise connection and simplifying the manufacturing process, combined with an optional connecting layer and an EMC layer for enhanced electromagnetic compatibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flame-resistant plastic battery housing is used, then the housing can be manufactured with simple materials, but it cannot withstand prolonged heat development during battery fire
Solution Approach 1:
The patent combines SMC base material with fire protection coating layers (mica/micanite) to create a composite structure that maintains mechanical integrity while providing extended fire resistance. The SMC material provides structural strength and the ceramic coating provides thermal barrier properties, allowing the housing to withstand prolonged heat exposure.
Solution Approach 2:
The fire protection coating is applied specifically to areas requiring thermal protection, such as the inner surface of the battery housing that faces the battery cells. This localized application provides fire resistance where most needed while maintaining manufacturing efficiency.
2Reliability
If fire protection layers are bonded to SMC components in separate steps, then fire protection is achieved, but manufacturing effort and process complexity increase considerably
Solution Approach 1:
The patent integrates the fire protection coating application into the SMC molding process itself. The coating layers are placed in the mold cavity along with the SMC blank, and both are formed simultaneously in one pressing operation. This eliminates separate coating and bonding steps, significantly reducing manufacturing complexity while maintaining fire protection effectiveness.
3Ease of manufacture
If a perforated fire protection coating is used, then vacuum can be created and plastic matrix can pass through for connection, but the coating structure becomes more complex
Solution Approach 1:
The fire protection coating is designed with a perforated structure containing numerous small openings. This porosity allows the plastic matrix to penetrate through the coating during pressing, creating automatic mechanical interlocking and chemical bonding. The perforations also enable vacuum transmission for proper blank formation. The regular pattern of holes adds minimal complexity while providing multiple functional benefits.
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 solution provides improved fire protection and reduced manufacturing effort, enabling the production of a cover structure that can withstand heat development and meet fire protection requirements while ensuring electromagnetic compatibility.
Implementation Method 1
the openings in the fire protection coating formed by the perforation are designed such that a plastic matrix of the SMC structure can pass through these openings or at least enter them during pressing and application of vacuum
Implementation Method 2
the connecting layer is made with a powder binder that is melted/softened during the SMC pressing process at the usually elevated mold temperature
Implementation Method 3
during the SMC pressing process at the usually elevated mold temperature
Data Source
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AI summary
The invention relates to a cover structure, an SMC mold and a method for producing a cover structure having an SMC main body which is pressed together with a flame-retardant coating in an SMC mold.