Enhanced Integrated Cooling-Protection Plate for Battery pack Underbody Impact Resistance in Electric Vehicles

In the quest for enhancing electric vehicle performance and safety, this paper presents a comprehensive investigation into the design and performance of high-voltage (HV) battery cooling plates featuring dedicated cooling channels, integrated with structural bottom protection members positioned at the bottom. The study aims to address the dual challenges of effective thermal management and enhanced crash protection in electric vehicles. Through a combination of Design iterations, Thermal performance evaluation and Crash simulations, the research evaluates the cooling efficiency and structural resilience of the proposed design. Findings reveal that the integrated cooling plates not only maintain optimal battery temperatures under various operating conditions but also significantly improve the vehicle's crashworthiness. The paper concludes with the results of numerical simulations, rigorously validated against the robust design requirement globally accepted for series components to ensure compliance with required standards. Additionally, a detailed manufacturing feasibility check was conducted to assess the potential for series production implementation. Conclusion: • The cooling efficiency of the HV battery plates improved by 5%, resulting in a more stable thermal environment for the battery cells. • The dedicated cooling channels reduced the maximum battery temperature by 2°C under peak load conditions, leading to more uniform temperature distribution & significant reductions in hot spots. • Integration of the structural crash member increased the energy absorption capacity by 33%, enhancing the vehicle's crashworthiness. • The combined design led to around 14% reduction in the overall weight of the battery module, contributing to better vehicle performance and efficiency.