Battery Housing Base Profile Structure for Crash Energy Absorption

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Solution Overview

Problem

Existing battery devices lack sufficient resistance to external force loads, which poses a challenge for accident safety and structural integrity, particularly in motor vehicles.

Innovation Solution

A battery device with a housing base that integrates a cooling system and a profile structure for force absorption, featuring a heat exchanger section and a profile structure section, where the heat exchanger section controls temperature through fluid flow and the profile structure enhances stiffness and energy absorption, using a one-piece or multi-piece housing base with hollow profile ducts and fluid ducts for optimal reinforcement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the housing base is reinforced with additional structural elements to resist external force loads, then the resistance to elastic and plastic deformations is improved, but the device complexity increases

Engineering Contradiction:

Improveresistance to external force loadsVSAvoidstructural complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent combines the cooling system and housing reinforcement into a single integrated housing base. The profile structure serves dual purposes: it provides structural reinforcement to resist external force loads and simultaneously functions as the cooling system through which coolant flows. This merging eliminates the need for separate structural reinforcement elements, thereby improving strength without proportionally increasing device complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The profile structure in the housing base performs multiple functions simultaneously: it provides mechanical reinforcement against external forces, serves as a thermal management system through integrated coolant channels, and contributes to the overall structural integrity. This multi-functionality allows the same structural element to address both strength requirements and thermal management needs without requiring additional separate components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Strength

If a profile structure is integrated into the housing base for reinforcement, then the resistance to elastic and plastic deformations is improved, but the manufacturing precision requirements increase

Engineering Contradiction:

Improveresistance to elastic and plastic deformationsVSAvoidhousing base fabrication precision

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The housing base is divided into multiple profile structures that can be manufactured separately and then assembled together. This segmentation allows each profile section to be manufactured with standard tolerances using conventional processes, and the modular nature facilitates quality control and assembly, thereby reducing overall manufacturing precision requirements while still achieving the desired structural reinforcement.

Inventive Principle:

Principle #1Segmentation

3Loss of energy

If the housing base is made thicker to absorb more energy during force application, then the energy absorption capacity is improved, but the weight of the battery device increases

Engineering Contradiction:

Improveenergy absorption capacityVSAvoidbattery device weight

Core Design Contradiction:

Loss of energyVSWeight of moving object

Solution Approach 1:

The profile structure incorporates hollow channels or cavities within the housing base that serve as energy-absorbing elements. These porous or hollow structures provide significant energy absorption capacity through controlled deformation during impact events, while the hollow nature reduces material usage and overall weight compared to solid thick sections. The coolant channels within the profile structure also contribute to energy dissipation through fluid dynamics during deformation.

Inventive Principle:

Principle #31Porous materials

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 enhanced resistance to elastic and plastic deformations, protects the cell stack and other components from damage, and acts as an energy absorber, ensuring the battery device can withstand significant force effects while maintaining optimal temperature control.

Implementation Method 1

the housing base has a heat exchanger section, through which fluid flows or can flow, for controlling the temperature of the cell stack

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

the profile structure can serve as energy absorber and/or impact absorber, at least to a certain degree, thus define a type of crash structure, in that it absorbs and/or dissipates the energy converted during an application of force by means of elastic and/or plastic deformation

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Implementation Method 3

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Data Source

PatentUS20230012363A1Battery device and use thereof in a motor vehicle

Publication Date: 2023.01.12 MAHLE INT GMBH

AI summary

A battery device of a motor vehicle is disclosed. The battery device includes a battery housing with a cell stack of rechargeable individual battery cells that are stacked one on top of the other with contact along a stack center axis in a stack direction arranged therein. The battery housing includes a housing base, on which the cell stack is arranged and held in a flat manner with contact. For controlling a temperature of the cell stack, the housing base has a heat exchanger section, through which fluid is flowable. The heat exchanger section is reinforced via a profile structure.