One-Piece Thermally Conductive Polymer Housing for EV Battery Cooling
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Solution Overview
Problem
Existing housing designs for heat-emitting elements, particularly in electric vehicles, are complex and costly to manufacture, and conventional cooling methods often result in inefficiencies due to separate components and materials with different thermal expansion coefficients.
Innovation Solution
A one-piece housing with a thermoplastic polymer heat sink integrated into the housing wall, utilizing a thermally conductive polymer composition with a thermal conductivity of ≥0.2 W/(m K) for efficient heat dissipation, manufactured through injection molding, which simplifies production and enhances heat transfer by using similar materials for the housing, bracket, and heat sink.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional separate components (housing wall, bracket, heat sink) are used, then manufacturing flexibility and material selection are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the housing wall, bracket, and heat sink into a single integrated component made of thermally conductive polymer. This consolidation eliminates the need for separate parts and assembly steps, directly reducing device complexity while maintaining manufacturing flexibility through injection molding processes.
Solution Approach 2:
The integrated housing component performs multiple functions simultaneously: it provides structural support (housing wall), secures the heat-emitting element (bracket function), and dissipates heat (heat sink function). This multi-functionality reduces the number of components needed while maintaining manufacturing versatility.
2Ease of manufacture
If separate heat sink and housing components are used, then material optimization is improved, but heat transfer efficiency and thermal expansion matching deteriorate
Solution Approach 1:
The patent uses a homogeneous thermally conductive polymer material for the entire integrated component, ensuring uniform thermal expansion characteristics throughout the housing wall, bracket, and heat sink. This eliminates thermal expansion mismatches that would occur with dissimilar materials while maintaining adequate heat dissipation performance.
3Adaptability or versatility
If multiple separate components are assembled, then manufacturing adaptability is improved, but production time and assembly complexity increase
Solution Approach 1:
The patent combines multiple components into a single injection-molded part, eliminating assembly steps and reducing production time. The integrated design maintains adaptability through modular functionality within the single component and ease of customization during the molding process.
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 reduces manufacturing complexity and enhances heat transfer efficiency by providing a significant increase in the heat-transferring surface area and matching thermal expansion coefficients, leading to improved cooling performance and long-term stability.
Implementation Method 1
At least the material of the heat sink comprises a first thermoplastic polymer with a thermal conductivity, determined according to ASTM E1461-01, of ≧0.2 W/(m K)
Data Source
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AI summary
A housing for at least one heat-emitting element (100), for example a battery element in an electric vehicle, the housing comprising: - a housing wall (200), - a holder (300) connected to the housing wall (200) for receiving the at least one heat-emitting element (100), and - a heat sink (400), which is arranged on a side of the housing wall (200) opposite the holder (300) and is connected to the housing wall (200). The housing wall (200), the holder (300) and the heat sink (400) are provided on the whole as a one-piece component, wherein the heat sink (400) comprises at least one channel (500) for a cooling medium, and at least one partial region of the heat sink (400) consists of a first thermoplastic polymer composition having a heat conductivity, determined according to ASTM E -01, of ≥ 0.2 W/(m K).