• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    Battery covers and methods of making battery covers are described. A battery cover described herein comprises a single sheet of material formed into a generally rectangular box shape with an opening formed along one side, the rectangular box shape being collapsible into a flattened shape for transport, and the material comprising a flexible laminate at least one layer of a synthetic fiber and a polymer film layer. The material has a thickness and other properties such that when the battery cover is deployed, the material substantially retains the rectangular box shape and, when the battery cover is collapsed into the flattened shape, the material maintains a spring force such that the battery cover unless it is restrained, would unfold into the rectangular box shape.
    公开号:AT14565U1
    申请号:TGM50025/2014U
    申请日:2014-02-21
    公开日:2016-01-15
    发明作者:
    申请人:Carcoustics Techconsult Gmbh；
    IPC主号:
    专利说明:

    description
    FLEXIBLE, COLLAPSIBLE BATTERY COVERING AREA OF REVELATION
    The present disclosure generally relates to a vehicle battery cover. BACKGROUND
    Vehicle and ship batteries conventionally have an anode electrode, a cathode electrode, and an insulating plate inside a cell case, and are often used as batteries. The battery is charged by a generator up to a certain threshold and discharged with increasing power demand from the vehicle. Such chemical processes are repeated during the life of the battery. The temperature of the battery components can have a large impact on these repeated cycles, thereby affecting the performance and durability of the components.
    SHORT DESCRIPTION
    The battery life decreases when the battery is exposed to extremely high temperatures that may be present in the vicinity of an automotive engine or exhaust system. This disclosure describes a flexible and collapsible battery enclosure which, among other advantages, reduces the transfer of heat to battery components. The disclosures herein may provide low cost, lightweight, and aesthetically pleasing battery covers. Moreover, the battery covers disclosed herein are collapsible into a folded form that allows for easy and cost-effective transportation and can spring back for installation in an open mold.
    An embodiment of the flexible battery cover has a single material web formed in a substantially rectangular box shape with an opening formed along one side. The cover is designed to be folded into a flattened shape for transport. The material comprises a layer of a thermoplastic polymer resin and a layer of a polymer film. The battery cover has a thickness such that when the battery cover is deployed, the material substantially retains the rectangular box shape and, when the battery cover is collapsed into the flattened shape, the material maintains a spring force such that the battery cover is unrestrained is unfolded in the rectangular box shape. Each fold line of the battery cover may have a series of perforations in the material.
    A method of making a flexible and collapsible battery cover in accordance with the present disclosure is also described herein. According to one method, material is cut from a single sheet, the material being a flexible laminate of a layer of synthetic fiber and a layer of a polymer film comprises. The single cut sheet of material forms a substantially rectangular box shape with an opening formed along one side. The material has a thickness such that when the battery cover is deployed, the material substantially retains the rectangular box shape and, when the battery cover is collapsed into the flattened shape, the material maintains a spring force. The spring force in the folded condition is such that if the battery cover is not restrained, it would unfold into the rectangular box shape.
    Variations in these and other aspects of the disclosure will be described in additional detail below.
    BRIEF DESCRIPTION OF THE DRAWINGS
    The description herein refers to the accompanying drawings, wherein like reference numerals refer to like parts throughout the several views, and wherein: Figure 1 is a perspective view of a typical automotive engine compartment and a battery installation site; FIG. 2 is an isometric view of a battery having a battery cover according to an embodiment of the teachings herein, shown in a characteristic, installed position; FIG. FIG. 3 is an isometric view of a battery cover according to an embodiment of the teachings herein; FIG. FIG. 4 is a side view of the battery cover of FIG. 3; FIG. Fig. 5 is a plan view of an output sheet for constructing the battery cover of Fig. 3; Fig. 6 is a partial sectional view of one side of a battery cover, as seen substantially from the line 6A-6A of Fig. 2; Fig. 7A is an isometric view of a battery cover in a deployed condition; FIG. 7B is an isometric view of a battery cover in a partially collapsed condition; FIG. FIG. 7C is an isometric view of a battery cover in a folded condition; FIG. and FIG. 8 is a flowchart of a method of manufacturing a battery cover according to an embodiment of the teachings herein.
    DETAILED DESCRIPTION
    Referring first to Fig. 1, an engine compartment 12 of a characteristic vehicle 10 is illustrated. The engine 14 (and associated engine components) are shown approximately in the center of the engine compartment 12. The battery 20 is shown arranged in the engine compartment 12 near the engine 14. As shown, the battery 20 has a positive electrode 22 and a negative electrode 24. A positive terminal connector 26 and a negative terminal connector 28 are connected to the positive and negative electrodes 22, 24 to transmit an electrical current to be distributed where needed in the vehicle. Although the battery 20 is shown in FIG. 1 near the engine 14, it is contemplated that the location of the battery 20 may vary depending on a particular application, including areas within the engine compartment 12, a passenger compartment, or a vehicle bay ¬raums. Due to the extreme conditions of the environment in which the battery 20 is located, as further described, the battery cover 30 may help to insulate and protect the battery 20.
    FIG. 2 illustrates a battery cover 30 mounted over the battery 20 with the battery cover 30 positioned above and on the battery 20 such that the four walls and the top of the battery cover 30 are in proximity or in contact with the four walls and the top of the battery 20 are located. Accordingly, the battery cover 30 is formed as a substantially rectangular box shape with an open surface, here the bottom surface. As seen in FIG. 2, the battery cover 30 may define terminal openings 32 to expose the positive and negative electrodes 22, 24 of the battery 20. This allows the attachment and removal of terminal connectors 26 and 28 while the battery cover 30 is in a built-in position. Although the terminal openings 32 are shown in a square shape and disposed at two of the corners of the top of the battery cover 30, other shapes, sizes and To consider bodies. For example, the terminal openings 32 could be disposed on the long front or rear peripheral surface to match positive and negative electrodes 22, 24 attached to a similar peripheral surface of the battery 20. The terminal openings 32 could also be disposed on different surfaces of the battery cover 30 to match the arrangement of the positive and negative electrodes 22, 24 of the battery 20.
    A recess 57 or other shaped cutouts near the open area of the battery cover 30 may be provided to allow clearance for other vehicle components when the battery 20 and the battery cover 30 are installed in the vehicle 10. Moreover, the battery cover 30 is shown to extend beyond the bottom of the battery 20 in the installed position, but it is to be appreciated that any or all of the front, rear or side walls are at one location above Although the battery cover 30 has an open area at the bottom, the open area could be any surface of the battery cover 30 that would allow it to be pushed over a battery. while allowing the folding and matching of the port openings 32 with the positive and negative electrodes 22, 24 as described below.
    Figures 3 and 4 illustrate the battery cover 30 in a deployed, fully assembled state. This is the state in which the battery cover 30 would be mounted on a battery such as the battery 20 , As shown, the battery cover 30 has a substantially rectangular box shape with an open bottom surface. The rectangular box shape may also be referred to as a five-sided rectangular box shape or a rectangular box shape with an opening instead of a surface. The battery cover 30 includes a front wall 36, a rear wall 37 opposite the front wall 36, a top wall 34, and left and right side walls 42. Although only the right side wall 42 is shown in Figures 3 and 4, its opposite left side wall 42 is the same a mirror image of the right side wall 42, which includes all the elements arranged thereon. With continued reference to FIG. 3, the battery cover 30 may include a label 35 on the top wall 34 to provide useful instructions or warnings to an end user of the vehicle. The battery cover 30 is not limited to a rectangular box shape and could have an approximately cubic box shape.
    The battery cover 30 may comprise a number of perforations. Desirably, the perforations are located at all locations where the battery cover 30 is folded into the rectangular box shape or folded into its collapsed configuration. Corner perforations 52 are disposed along the corners of the fully assembled battery cover 30. The corner perforations 52 allow the battery cover 30 to be at approximately the angle where the front, rear, top and side walls 36, 37, 34 and 42 meet when assembled from a piece of material as described below. Fold perforations 50a, 50b are disposed on the front side 36 and the side walls 42 and, together with the corner perforations 52, allow the battery cover 30 to be folded into a collapsed configuration in which the battery cover 30 occupies less space in a transport container. The folding perforations 50b on the sidewalls 42 act as a hinge that allows the sidewalls 42 to fold inwardly during collapse. The folding perforation 50a in the front wall 36 divides the front wall 36 into a first front wall section 38 disposed between the top wall 34 and the folding perforations 50a and a second front wall section 40 disposed between the folding perforations 50a and the open bottom surface of the battery cover 30 is arranged. In the collapsed configuration (see FIG. 7), the front wall 36 and the side walls 42 are folded along the fold perforations 50a, 50b and the top, front, back and side walls 34, 36, 37 and 42 can be relative to one another turn 52 along the corner perforations.
    As mentioned, it is desirable that the battery cover 30 from a
    Piece of material is constructed. Referring to Figure 5, the battery cover 30 is illustrated in a flat sheet configuration unassembled state before the material is manipulated to form its built-up state illustrated in Figures 2-4. It is contemplated that the battery cover 30 may be cut from sheets of the layered material using a stamping operation, however, other methods of cutting or trimming the material may be used. Still referring to FIG. 5, perforations 50a, 50b, 52 may be generated using a punching or punching process while battery cover 30 is still in the substantially flat or unfolded state. The perforations 50a, 50b, 52 may be formed as part of the cutting operation or in a previous or subsequent step. A punch may include a cutting structure to cut the outer edges of the battery cover 30 and may have a perforation structure configured to mate the material the battery cover 30 to compress or cut through this. The corner perforations 52 and folding perforations 50 may be formed in similar size and depth as described herein, however, it is contemplated that the perforations of the battery cover 30 may vary in size and depth. It should be noted that in accordance with the teachings herein, it is possible to construct the battery cover 30 from more than one piece of material. However, this adds process steps to form the battery cover 30, and can make the battery cover 30 thicker when in the collapsed configuration due to the need to interconnect the individual pieces of material. This is less desirable than using a single sheet of material.
    Once the battery cover 30 is cut and the perforations 50a, 50b, 52 are made, the battery cover 30 may be kinked along the corner perforations 52 to create the desired shape of the constructed battery cover. As in the FIG. 4 and 5, the side walls 42 may include a first side portion 44, a second side portion 46, and a third side portion 48. Each of the first, second and third side portions 44, 46, 48 is fixedly attached to the other two side portions to cause the battery cover 30 to maintain the built-up state. The three side portions may be overlaid by overlaying first portion strips 54 of the upper wall 34 via the second side portion 46 and third side portion 48 of the sidewalls 42 and by overlaying a second portion tab 58 of the front wall 36 via the third side portion 48 of the sidewalls 42. The strips 54, 58 may be attached to the side sections 46, 48 via an ultrasonic welding process as well as other conventional fastening means, such as adhesives, staples, staples, etc. In the ultrasonic welding process, ultrasonic vibrations of about 20 to 30 kilohertz (kHz) are locally applied to the pressurized material to produce a solid weld. No connecting bolts, nails, brazing materials or adhesives are required, which saves both cost and weight. In Figs. 3 and 4, weld points 56 are shown on the sidewalls 42 where the ultrasonic welding was located and made a weld between the two-ply sheets of material. All in all, six spot welds 56 are shown on each side wall 42, but it should be noted that the size and number of spot welds may vary depending on the application. Although the embodiments described herein have the attachment and overlapping portions of the material on opposite short sides of the rectangular box shape, it is contemplated that the material may be cut in such a manner that the attachments are opposite to other ones Walls of the rectangular box shape are arranged, such as the front wall 36 and the rear wall 37.
    In Fig. 6, the internal composition of the material of the battery cover 30 is further described. FIG. 6 is a partial cross-sectional view of the front wall 36 as seen substantially from the line 6A-6A in FIG. 2. As previously mentioned, the battery cover 30 may preferably be constructed of a laminate material sheet. In this embodiment, the laminate material sheet of the battery cover 30 has at least two different materials laminated together. An inner layer 60 is the layer of material closest to the interior of the assembled battery cover 30 and includes an inner surface 66 that contacts or is proximate to the battery 20 when the battery cover 30 is in the installed position of FIG. 2 located. The inner layer 60 may comprise a synthetic fiber material and, in particular, a polyethylene terephthalate (PET) fiber material. Other polymer fibers may be used, such as polyester or polypropylene, with the aim of providing a fully recyclable end product. The inner layer 60 provides a relatively poor path for heat conduction through the many packed fibers and is thus a good insulator.
    The thickness of the inner layer 60 may vary depending on the application, but it is to be considered that the thickness t1 of a PET fiber inner layer may be less than 1 mm thick. Similarly, the density of the inner layer 60 may vary based on the application. In certain embodiments, a PET fiber having a surface or paper density of 355 grams per square meter (gsm) may be used.
    The battery cover 30 further includes a film layer 62 disposed immediately on the outside of the inner layer 60. The material of the film layer 62 may be a polymer film and in particular a polyethylene (PE) film. The thickness t2 of the film layer 62 may vary, but may be less than 1 mm. The density of the PE film of the film layer 62 may be about 145 gsm. The film layer 62 is less porous than the PET fiber of the inner layer 60 and may provide protection against convective heat transfer by restricting or preventing airflow (eg, from the radiator) through the battery cover 30.
    The battery cover 30 may optionally include an outer layer 64 disposed farther outward from both the inner layer 60 and the film layer 62. The outer layer 64 includes an outer surface 68 of the battery cover 30. Similar to the inner layer 60, the outer layer 64 may comprise a synthetic fiber material, and more particularly a PET fiber. The fibrous outer layer 64 may contribute to additional thermal and physical protection of the battery 20 as well as provide an aesthetically pleasing outer surface 68. The thickness of the outer layer 64 may also vary depending on the application, but it is contemplated that a thickness of a PET fiber outer layer may be up to 1 mm in a design in which the outer layer 64 is not needed for thermal protection , The outer layer 64 may have a surface density of about 100 gsm, but other densities of the PET fiber should be considered.
    The PET fiber of the inner layer 60 and the outer layer 64 coupled to the PE film of the film layer 62 may provide thermal protection to restrict both heat transfer through conduction and convection through the battery cover 30 , The PET fiber of the battery cover 30 may have hydrophobic properties wherein the inner layer 60 and the outer layer 64 are water repellent and fluid resistant. This reduces or eliminates any weight gain due to water absorption and reduces the drying time of the battery cover 30. In addition, the PET fiber and the PE can be used. Film to protect the battery 20 from foreign body impacts.
    The perforations of the battery cover 30 may be further explained with reference to FIG. 6. The perforations are shown as depressions in the battery cover 30 with a Tiefen¬ distance d. As mentioned above, this can be achieved by a stamping operation wherein the punch would comprise a series of protruding structures designed to either compress certain areas along a line of perforation or into the material along a perforation line (either partially or completely through the material ) to cut. If the material is compressed in areas along perforation lines, this can lead to a compressed inner section 70, a compressed film section 72 and a compressed outer section 74 immediately inside the folding perforation 50a, as shown in FIG. As the punch cuts along the perforation line through the material, there would be a corresponding series of recesses or gaps in the material, such as that illustrated for the corner perforation 52 in FIG.
    It is contemplated that the optimum composition and thickness of the layers of the material can be determined along with the desired properties of the perforation lines using computer-aided or real-world testing. For example, computer modeling can help heat transfer at the location of battery 20 to determine the type and amount of material for adequate protection.
    FIGS. 7A-7C illustrate the ability of the battery cover 30 to manipulate from an unfolded state in FIG. 7A to a collapsed state. By folding the battery cover 30, more efficient storage and transportation of the battery cover 30 is enabled. Folded battery covers occupy less space, so that a higher amount of battery covers can be folded and placed in transport containers. As illustrated in FIGS. 7B and 7C, the battery cover may be folded along the fold perforations 50a, 50b in both the front wall 36 and the side walls 42. During the folding operation, the hinges formed by the folding perforations 50b in the side walls 42 allow the centers of the walls 42 to run in a direction against an inside of the battery cover 30. The first front wall section 38 and the second front wall section 40 fold relative to one another along the fold perforation 50a. In addition, each of the front, rear, top and side walls 36, 37, 34 and 42 may fold relative to each other along the corner perforations 52. In the folded position of FIG. 7C, the upper wall 34, the first front wall section 38, the second front wall section 40 and the rear wall 37 are all in a substantially parallel position.
    Due to a combination of the thickness, resilience and other properties of the material that make up the battery cover 30, the battery cover 30 maintains a spring force to move the battery cover 30 into the unfolded, rectangular box shape of FIG. 7A under bias. That is, as long as the battery cover 30 is in a deflated condition, the material substantially retains the unfolded rectangular box shape, and when the battery cover 30 is in a collapsed state, the battery cover 30 will deploy to form the rectangular box shape, if provided she is not held back in the folded position. This spring effect causes the battery cover 30 to unfold into the rectangular box shape after an obstruction is removed, such as is removed between adjacent, folded battery covers in a full transport or storage container. This deployment activity can save time in installing the battery cover 30 by reducing the handling required by a fitter.
    A method of manufacturing the battery cover 30 may be described as follows, and is illustrated as method 800 for ease of explanation in a flow chart in FIG. 8. However, steps may be taken in different orders and / or concurrently in accordance with this disclosure. In addition, steps in accordance with this disclosure may be made with other steps that are not presented and described herein. Moreover, not all illustrated steps may be required to perform a method in accordance with the disclosed subject matter.
    As illustrated in step 802, the material properties are selected based on the particular application and location of the battery 20. In step 804, an empty sheet of the selected laminate material, which is large enough to provide a cutout of the battery cover 30 in a continuous piece, is cut to the required size and shape. As has been described, the cutting operation can be achieved using a punching or punching operation. The perforations are punched in the bow in step 806 and, as previously mentioned, the perforations can be punched simultaneously with the punching operation. To create the perforations, the punch may compress or cut through the material of the battery cover 30.
    In step 808, the battery cover 30 is constructed into the rectangular box shape as described above. In this implementation, the battery cover 30 is bent approximately at right angles at the corner perforations 52, at which two walls each meet. The sidewalls 42 are configured with a first side portion 44, a second side portion 46, and a third side portion 48, each overlapping the other two. In step 810, overlapping portions of each side portion are ultrasonically welded together as described above.
    It should be appreciated that the battery cover 30 may be attached to the battery 20 and / or the vehicle 10 in a variety of ways. The battery cover 30 may be mounted over the battery 20 and held in place with frictional and gravitational forces or with additional fasteners. It is also contemplated that the terminal connectors and / or cabling may aid in retaining the battery cover 30.
    Although the embodiments described herein have a total of three different sub-layers of the battery cover 30, it is further contemplated that only one layer of the PET fiber is used. For example, the outer layer 64 could be omitted, and the battery cover 30 could include the inner layer 60 and the film layer 62.
    Although the invention has been described in connection with particular embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary is intended to cover various modifications and equivalent arrangements, which are within the scope of the appended claims are covered, wherein the scope of protection is the widest interpretation to be added, so as to cover all such modifications and equivalent arrangements as permitted by law.
    权利要求:
    Claims (20)
    [1]
    Claims 1. A flexible and collapsible battery cover comprising: a single sheet of material formed into a substantially rectangular box shape having an opening formed along one side, the rectangular box shape being collapsible into a flattened shape for transport and the material a flexible laminate of at least one layer of a synthetic fiber and a polymeric film layer, the material having a thickness such that: when the battery cover is deployed, the material substantially retains the rectangular box shape; and when the battery cover is collapsed into the flattened shape, the material maintains a spring force such that the battery cover, if not held, would unfold into the rectangular box shape.
    [2]
    2. Battery cover according to claim 1, further comprising hinges on gegenüberliegen¬den end faces of the rectangular box shape, wherein the hinges have a plurality of folding lines.
    [3]
    3. The battery cover of claim 1, wherein each fold line of the plurality of fold lines comprises a series of perforations in the material.
    [4]
    4. The battery cover of claim 1, further comprising: two electrode openings through a surface of the battery cover that is opposite the opening, wherein each of the two electrode openings is disposed at opposite corners along a long edge of the surface.
    [5]
    5. Battery cover according to claim 2, wherein the opposite end surfaces along short edges of the rectangular shape are arranged and have overlapping parts of the einzi¬gen arc.
    [6]
    6. Battery cover according to claim 5, wherein the overlapping parts are ultrasonically welded together.
    [7]
    7. The battery cover according to claim 1, which is attached to a battery, wherein the opening is at a bottom surface of the rectangular box shape and a height from an upper surface of the rectangular prism shape to the bottom surface is shorter than a height of the battery.
    [8]
    8. The battery cover according to claim 4, wherein terminals of the battery extend from respective electrode openings in a surface of the rectangular box shape to the outside.
    [9]
    A battery cover according to claim 1, wherein the synthetic fiber is polyethylene terephthalate.
    [10]
    10. The battery cover according to claim 1, wherein the polymer film layer is a polyethylene film layer.
    [11]
    11. The battery cover of claim 9, wherein the polyethylene terephthalate has a surface density of about 335 grams per square meter.
    [12]
    12. The battery cover of claim 10, wherein the polyethylene has an areal density of about 145 grams per square meter.
    [13]
    13. A method of making a flexible and collapsible battery cover, the method comprising: cutting a material from a single sheet, the material comprising a flexible laminate of a layer of a synthetic fiber and a layer of a polymeric film; rectangular box shape with an opening formed along one side using the single sheet of material, wherein the rectangular box shape can be folded into a flattened shape for transport and wherein the material has a thickness such that: when the battery cover is in the rectangular box shape the material substantially maintains the rectangular box shape; and when the battery cover is collapsed into the flattened shape, the material maintains a spring force such that the battery cover, if not held, would unfold into the rectangular box shape.
    [14]
    14. The method of claim 13, wherein the cutting comprises a punching operation.
    [15]
    15. The method of claim 13, further comprising: punching a series of perforations on each fold line of the battery cover into the material.
    [16]
    16. The method of claim 13, wherein forming comprises buckling the material at approximately ninety degree angles along eight edges of the rectangular box shape and securing overlapping portions of the material together on opposite sides of the rectangular box form.
    [17]
    17. The method of claim 16, wherein said attaching comprises ultrasonic welding.
    [18]
    18. The method of claim 13, wherein the cutting creates terminal openings and leads to the terminal openings at opposite corners of a surface of the battery cover along a long edge of the rectangular box shape.
    [19]
    The method of claim 13, wherein the synthetic fiber is polyethylene terephthalate.
    [20]
    The method of claim 13, wherein the polymeric film layer is a polyethylene film layer. For this 7 sheets drawings
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    同族专利:
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    法律状态:
    优先权:
    申请号 | 申请日 | 专利标题
    US14/169,726|US9793520B2|2014-01-31|2014-01-31|Flexible folding battery cover|
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