Hyundai Motor Co. and Kia Corp. have submitted a patent application for an electric vehicle battery design intended to reduce the risk of fires by transforming the battery housing into an integrated cooling structure. The concept is designed to minimize temperature differences across the battery pack while improving overall vehicle stability.
According to Pulse, the English-language service of Maeil Business News Korea, the patent—titled “Battery Storage Case”—was filed with the U.S. Patent and Trademark Office in November 2024, following partial disclosure in late 2023. The filing centers on the cooling design of the lower battery case. Industry analysts note that the level of technical detail suggests the technology has progressed beyond the conceptual review stage and could be incorporated into future electric vehicle platforms within the next two years.
At the heart of the patent is a grid-style cooling channel positioned beneath the battery pack. Unlike conventional cooling systems that rely on one-way flow, the new design features intersecting sub-channels that allow coolant to circulate both horizontally and vertically. This multi-directional flow enables more uniform cooling by distributing coolant across multiple routes, helping maintain consistent temperatures across the entire underside of the battery.
Many current EV batteries experience uneven cooling because simplified flow paths can cause heat to build up in certain cells or corners, increasing the likelihood of overheating. The proposed design addresses this issue by embedding cooling channels directly into the lower battery case itself. As a result, it removes the need for separate, thin cooling plates commonly used in layered battery structures, which are vulnerable to stress concentration at connection points during collisions.
Integrating the cooling system into the battery case allows impact forces and physical loads to be spread more evenly across the structure. This not only strengthens the vehicle’s frame but also enhances cooling performance. Given the importance of the lower vehicle structure to crash safety and durability, the new design is expected to significantly improve battery pack stability.
“With the growing adoption of electric vehicles, concerns from consumers and regulators over battery fires are intensifying. Battery fires are difficult to extinguish and carry a high risk of casualties once they occur. Hyundai and Kia’s decision to pursue patent protection in the U.S. is widely seen as an effort to safeguard proprietary technology while reinforcing safety standards for global markets.”
