ENCAPSULATED EMI/RFI SHIELDING FOR A NON-CONDUCTIVE THERMOSETTING PLASTIC COMPOSITE PHEV BATTERY COVER

• US 20120100414A1
• Filed: 10/22/2010
• Published: 04/26/2012
• Est. Priority Date: 10/22/2010
• Status: Abandoned Application

• Current Assignee: GM Global Technology Operations LLC (General Motors Company)
• Original Assignee: GM Global Technology Operations Incorporated (General Motors Company)
• Inventors: Sonta, Kestutis A.
• Application Number:
  US12/910,174
• Publication Number:
  US 20120100414A1
• Time in Patent Office: Days
• US Class Current: 429/163
• CPC Class Codes: B60K 2001/0411 Arrangement in the front part of the vehicle
• CPC Class Codes: B60K 2001/0416 Arrangement in the rear part of the vehicle
• CPC Class Codes: H01M 2220/20 Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 50/24 adapted for protecting batteries from their environment, e.g. from corrosion thermal insulation H01M10/658
• CPC Class Codes: H01M 50/276 Inorganic material
• CPC Class Codes: H01M 50/278 Organic material
• CPC Class Codes: H01M 50/28 Composite material consisting of a mixture of organic and inorganic materials
• CPC Class Codes: H01M 50/282 having a layered structure
• CPC Class Codes: H05K 9/0045 being rigid plastic containers having a coating of shielding material
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles

Abstract

A cover for a high voltage vehicle battery is disclosed that is made of a light weight, non-conductive thermoset plastic composite, such as a polyester resin matrix, and includes an EMI/RFI shield. In one embodiment, the EMI/RFI shield is a Faraday cage including a ferrous mesh that is molded into the thermoset plastic composite so that it is completely encapsulated therein. In another embodiment, the EMI/RFI shield is an acrylic polymer coating including nickel plated copper flakes formed on an outside surface of the thermoset plastic composite.

Claims

1. A protective cover for a battery comprising:

a single piece housing including a top plate and side plates forming an enclosure, said housing being formed from a molded non-conductive thermoset plastic composite; and

an electromagnetic interference and radio frequency interference (EMI/RFI) shield formed on or in the housing.

2. The cover according to claim 1 wherein the thermoset plastic composite includes a polyester resin matrix having glass fibers.

3. The cover according to claim 2 wherein the glass fibers have a length in the range of 100-150 mm.

4. The cover according to claim 1 wherein the EMI/RFI shield is a Faraday cage defined by a ferrous metal mesh that is encapsulated within the thermoset plastic composite.

5. The cover according to claim 1 wherein the EMI/RFI shield is an acrylic polymer coating including metal particles formed on a surface of the housing.

6. The cover according to claim 5 wherein the metal particles are nickel plated copper flakes.

7. The cover according to claim 5 wherein the acrylic polymer coating is formed only on outside surface of the housing.

8. The cover according to claim 1 wherein the housing includes a circumferential flange extending around the housing for mounting the housing to a mounting member.

9. The cover according to claim 1 wherein the battery is a high voltage battery on an electric or hybrid vehicle.

10. A protective cover for a high voltage battery on an electric or hybrid vehicle, said cover comprising:

a single piece housing including a top plate and side plates forming an enclosure, said housing being formed from a molded non-conductive thermoset plastic composite; and

a Faraday cage defined by a ferrous metal mesh encapsulated within the thermoset plastic composite.

11. The cover according to claim 10 wherein the thermoset plastic composite includes a polyester resin matrix having glass fibers.

12. The cover according to claim 11 wherein the glass fibers have a length in the range of 100-150 mm.

13. The cover according to claim 10 wherein the housing includes a circumferential flange extending around the housing for mounting the housing to a mounting member.

14. A protective cover for a high voltage battery on an electric or hybrid vehicle, said cover comprising:

a single piece housing including a top plate and side plates forming an enclosure, said housing being formed from a molded non-conductive thermoset plastic composite; and

an acrylic polymer coating including metal particles formed on a surface of the housing.

15. The cover according to claim 14 wherein the thermoset plastic composite includes a polyester resin matrix having glass fibers.

16. The cover according to claim 15 wherein the glass fibers have a length in the range of 100-150 mm.

17. The cover according to claim 14 wherein the metal particles are nickel plated copper flakes.

18. The cover according to claim 14 wherein the acrylic polymer coating is formed only on outside surface of the housing.

19. The cover according to claim 14 wherein the housing includes a circumferential flange extending around the housing for mounting the housing to a mounting member.