Integrated EV Battery Tray Cooling for Crash-Resistant Packs
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Solution Overview
Problem
Existing battery carriers for electric vehicles face challenges in optimizing cooling performance and crash resistance while maintaining a simplified design and reducing material usage and production costs.
Innovation Solution
A battery tray made from a hot-formed and press-hardened sheet metal blank with integrated cooling channels and reinforced side walls, featuring a cooling channel structure formed from the same material as the base, and a cover plate for efficient heat transfer, along with serpentine channels and additional beads for enhanced cooling and crash protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If separate cooling channels are added to the battery tray, then cooling performance is improved, but device complexity and production costs increase
Solution Approach 1:
The cooling channels are integrated directly into the battery tray base as ribs or embossments, merging the cooling function with the structural component. This eliminates the need for separate cooling plates or channels, reducing part count and assembly complexity while maintaining effective cooling performance through direct thermal contact with batteries
2Strength
If more material is used to reinforce the battery tray, then crash resistance is improved, but weight and production costs increase
Solution Approach 1:
Reinforcement ribs are strategically positioned only in high-stress areas of the battery tray, such as corners and regions subject to impact forces during crashes. This localized reinforcement provides enhanced crash resistance where needed while minimizing overall material usage and weight compared to uniform thickening of the entire tray
3Ease of manufacture
If the battery tray design is simplified, then production costs are reduced, but cooling performance and crash resistance may deteriorate
Solution Approach 1:
The battery tray base is designed to perform multiple functions simultaneously: it provides structural support, incorporates cooling channels through integrated ribs or embossments, and includes reinforcement features for crash resistance. This multi-functionality is achieved through a single stamping process that forms all features in one operation, simplifying manufacturing while delivering comprehensive performance
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 enhances cooling performance, reduces material usage and production costs, and improves crash resistance by optimizing heat transfer and structural integrity, while preventing coolant leaks and mechanical defects.
Implementation Method 1
heat transfer is optimized, thereby efficiently increasing the cooling performance... Heat can then be transferred by means of heat conduction from the battery floor into the cooling channels
Implementation Method 2
The battery tray is made from a sheet metal blank as a hot-formed and press-hardened component. A sheet metal blank made of a hardenable steel alloy, for example, 22MnB5
Data Source
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AI summary
The invention relates to a battery carrier for an electric vehicle, comprising a battery tray (1) produced as a hot-formed and press-hardened component from a sheet steel blank, comprising a base (2) and side walls (3, 4) rising from the base (2) and having a flange (5) running around the top of the battery tray (1) and projecting outwards. A cooling channel structure (9) is formed in one piece and from a uniform material in the base (2), wherein a cover plate (12) is arranged on the base (2) in the battery tray (2) or wherein a cover plate (12) is arranged beneath the base (2) of the battery tray (1), such that cooling channels (13) are formed between the cooling channel structure (9) and the cover plate (12).