EV Battery Housing Structure With Variable Thickness and Cooling

Solution Overview

Problem

Existing battery housings for electric vehicles face challenges in balancing high load-bearing capacity with low weight and efficient cooling, while maintaining mechanical integrity and crash resistance.

Innovation Solution

A housing assembly for electrical storage in electric vehicles, comprising a frame with variable thickness frame elements and a base with integrated cooling channels, allowing for customizable material distribution based on load requirements, and a detachable cover, enhancing strength and rigidity where needed.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If uniform thickness frame elements are used throughout, then manufacturing is simpler, but weight cannot be optimized and load-bearing capacity is compromised in critical areas

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidhousing assembly weight

Core Design Contradiction:

Ease of manufactureVSWeight of moving object

Solution Approach 1:

The frame elements are designed with variable cross-sectional thicknesses, where different sections have different thicknesses tailored to their specific load requirements. Critical areas experiencing higher loads have increased thickness for enhanced strength, while non-critical areas have reduced thickness to minimize weight. This local differentiation of geometric properties allows the housing assembly to achieve optimal weight reduction while maintaining necessary structural integrity throughout.

Inventive Principle:

Principle #3Local quality

2Strength

If frame thickness is increased in all areas, then load-bearing capacity and crash resistance improve, but weight increases and material costs rise

Engineering Contradiction:

Improveload-bearing capacityVSAvoidhousing assembly weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The frame elements are designed with variable cross-sectional thicknesses, where different sections have different thicknesses tailored to their specific load requirements. Critical areas experiencing higher loads have increased thickness for enhanced strength, while non-critical areas have reduced thickness to minimize weight. This local differentiation of geometric properties allows the housing assembly to achieve optimal weight reduction while maintaining necessary structural integrity throughout.

Inventive Principle:

Principle #3Local quality

3Strength

If more material is used throughout the frame, then strength and rigidity increase, but weight increases and manufacturing cost increases

Engineering Contradiction:

Improveframe strengthVSAvoidmaterial quantity

Core Design Contradiction:

StrengthVSQuantity of substance

Solution Approach 1:

The frame elements are designed with variable cross-sectional thicknesses, where different sections have different thicknesses tailored to their specific load requirements. Critical areas experiencing higher loads have increased thickness for enhanced strength, while non-critical areas have reduced thickness to minimize weight. This local differentiation of geometric properties allows the housing assembly to achieve optimal weight reduction while maintaining necessary structural integrity throughout.

Inventive Principle:

Principle #3Local quality

4Temperature

If cooling channels are integrated into the base, then cooling efficiency improves, but manufacturing complexity increases

Engineering Contradiction:

Improvecooling efficiencyVSAvoidhousing assembly complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The cooling channels are integrated directly into the base structure of the housing assembly, merging the cooling function with the structural support function. This integration eliminates the need for separate cooling components and reduces the overall number of parts. The base is designed with internal passages that serve both as structural elements and as coolant flow paths, thereby improving cooling efficiency while actually reducing manufacturing complexity through consolidation.

Inventive Principle:

Principle #5Merging (Combining)

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 achieves a lightweight, cost-effective housing assembly that withstands high loads, provides efficient cooling, and maintains mechanical integrity, including crash resistance, while optimizing material usage.

Implementation Method 1

a base which is connected to the frame in such a way that a sealed shell is formed, and a cover which is detachably connectable to the frame... The base may include, e.g., an integral cooling structure through which a coolant may flow

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentUS12438213B2Housing arrangement for receiving electrical storage

Publication Date: 2025.10.07 MUHR UND BENNDER KG

AI summary

The disclosure relates to a housing assembly for receiving electrical storage means for an electrically drivable motor vehicle, comprising: a frame comprising a plurality of frame elements made of a metallic material, with at least one of said frame elements having a variable sheet thickness over a longest length; a base connected to the frame so as to form a sealed shell; and a cover releasably connectable to the frame, wherein the base, the frame and the cover enclose a receiving space for electrical storage means, wherein the base comprises an integral cooling structure through which a coolant can flow.