Vehicle Underbody Battery Cooling Layout for Space-Constrained Packs

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Solution Overview

Problem

Existing vehicle underbodies face challenges in providing sufficient space for large-capacity battery modules, inefficient cooling methods, and require separate assembly processes, leading to increased weight and complexity.

Innovation Solution

An underbody structure with a tray member fastened directly to the vehicle body frame, incorporating a cover member with integrated refrigerant flow paths and irregularities for enhanced cooling and rigidity, allowing direct battery module attachment and minimizing assembly steps.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If a large-capacity battery module is mounted to increase driving distance or power, then the vehicle performance is improved, but the mounting space requirement increases

Engineering Contradiction:

Improvevehicle powerVSAvoidmounting space

Core Design Contradiction:

PowerVSArea of stationary object

Solution Approach 1:

The battery module is directly fastened to the vehicle body frame, merging the battery mounting function with the vehicle frame structure. This eliminates the need for separate mounting brackets or support structures, thereby maximizing the use of available space while accommodating large-capacity battery modules.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The underbody structure utilizes the vertical space beneath the vehicle by forming a receiving portion that accommodates the battery module in the vertical dimension. This allows efficient use of the underbody cavity space, enabling larger battery capacity without increasing the vehicle's footprint.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Device complexity

If air-cooling method is used to cool the battery module, then the cooling system is simple, but the cooling efficiency is insufficient when driving a vehicle

Engineering Contradiction:

Improvecooling system complexityVSAvoidbattery module temperature

Core Design Contradiction:

Device complexityVSTemperature

Solution Approach 1:

The patent employs liquid cooling by forming a cooling layer with coolant flow paths in direct contact with the battery module. This hydraulic cooling system efficiently removes heat from the battery module during vehicle operation, maintaining optimal temperature without requiring complex cooling infrastructure.

Inventive Principle:

Principle #29Pneumatics and hydraulics

3Device complexity

If air-cooling method is used, then no separate cooling infrastructure is needed, but a separate space for forming air flow path is required

Engineering Contradiction:

Improvecooling infrastructureVSAvoidair flow path space

Core Design Contradiction:

Device complexityVSVolume of moving object

Solution Approach 1:

The cooling layer is integrated directly into the underbody structure, merging the cooling function with the structural component. The cooling layer includes flow paths formed within the underbody itself, eliminating the need for separate cooling ducts or air flow channels, thereby saving valuable underbody space.

Inventive Principle:

Principle #5Merging (Combining)

4Adaptability or versatility

If separate assembly process is used for battery pack mounting, then the battery module can be independently assembled, but the assembly process becomes complex and time-consuming

Engineering Contradiction:

Improvebattery module independenceVSAvoidassembly time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The underbody is designed with a receiving portion that is pre-configured to directly receive and fasten the battery module. This preliminary design of the mounting interface allows for quick installation by simply fastening the battery module to the frame, significantly reducing assembly time while maintaining independent battery module assembly capability.

Inventive Principle:

Principle #10Preliminary action

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 efficient space utilization, improved cooling efficiency, reduced weight, and simplified assembly by integrating the battery module directly to the vehicle frame, enhancing both performance and safety.

Implementation Method 1

the cover member includes a flow path through which a refrigerant fluid moves

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentUS20250206126A1Battery cooling arrangement in an underbody of a vehicle

Publication Date: 2025.06.26 LG ENERGY SOLUTION LTD

AI summary

An underbody for a vehicle, can include at least one battery module, a tray member fastened to a lower portion of a vehicle body frame and including a receiving portion having a structure with an open lower surface to accommodate the at least one battery module, a cover member to cover the open lower surface of the receiving portion, and a thermal interface material interposed between the at least one battery module and the cover member. The cover member includes a flow path to circulate a refrigerant fluid.