Liquid Cold Plates & Liquid Cooling Systems in electric Vehicle (Part 1)

Liquid Cold Plates & Liquid Cooling Systems in Electric Vehicle

Much larger heat loads are being produced by advancements including faster charging, better cabin features, longer lasting, more performing batteries, increased connectivity, more precise and connected sensors, improved system monitoring, and faster charging. Apart from the improved functionality and performance, manufacturers are also requesting form factors that are lighter and smaller. If not handled properly and efficiently, the excess heat produced by so much power in such a small form can quickly cause system failures and pose a risk to passenger safety. 

With every new model that comes out, electric vehicles (EVs) will get safer, more dependable, lighter, and more connected. For every new development to be tested and proven safe and reliable, cooling systems must evolve before vehicle innovation.

Electric Vehicle

Through close collaboration with leading eMobility innovators and design teams over the past 20 years, Boyd Corporation and its Thermal Division, Aavid, have made sure that our thermal management solutions surpass industry breakthroughs and spur forward future innovation.

Because of our tight collaboration, Boyd engineers have been able to start development early for better thermal solutions and system integration, impact our research and development, and foresee forthcoming market developments, industry trends, and growing design needs. This approach not only results in more reliable and cost-effective cooling, but it also gives OEMs a major competitive edge, a quicker time to market, and lower total expenses.

TACKLING IMPORTANT EMOBILITY COOLING DIFFICULTIES

GENERAL ENVIRONMENTAL & USE AWARENESS

Environmental conditions are one of the most important factors to take into account when it comes to all thermal management systems in electric vehicles. When operating in conditions with varying temperature extremes, humidity levels, precipitation, exposure to sand and saltwater, and other environmental factors, vehicles must be able to perform with guaranteed safety, dependability, and performance. Along with many other potential hazards, vehicles may encounter rough terrain, intense shock and vibration, collisions, electromagnetic interference from cutting-edge electronic systems, and more. Crucial parts and systems need to be made to be as affordable, easily maintained, and serviceable as possible, but also to guard against known potential risks.

Read Also : Electric Drive Train In EV

The first step in optimized design is to choose the materials that are most appropriate for a given performance and environmental exposure. These materials are then combined with streamlined geometries to integrate multiple functions into a solution that reduces material and assembly costs. An example of this would be combining structural and protective functionality into a cooling solution. Thorough testing and quality control are also essential for sustaining dependable, high performance in demanding settings.

BATTERY & INVERTER COOLING CHALLENGE

Battery EV

The two most important technologies driving the growth and adoption of eMobility are inverters and batteries, which transform battery energy into mechanical power for vehicle propulsion. 

Because of the link between falling battery costs and the uptake of electric vehicles, engineers are concentrating their efforts on lowering battery costs. Innovation in the form of lighter, smaller, and higher power batteries has been fueled by advancements in battery capacity, charge speed, and reliability, which have improved performance and reduced total cost of ownership. Battery design innovation and cost-cutting strategies are resulting in higher-density heat loads that need to be controlled in a small form factor. While size, weight, and performance requirements must be met, cooling systems must also maintain battery cost reduction.

The higher heat flux inverters required to operate the vehicle on electricity add another level of complexity to the required heat rejection systems. High heat flux inverters and batteries function together despite sometimes having quite different cooling needs. The management of battery thermals depends on optimizing the surface area that is capable of receiving consistent cooling. Localized high power density heat sources that necessitate local hot spot heat spreading and cooling cause variations in inverter power density. To maximize vehicle performance, inverters must also be cooled below critical temperatures. In order to save space, weight, and money, a cooling system has to be designed to optimally cool batteries and different inverters using the same system, coolant, and cooling loop.