电动汽车液体冷板案例研究
简介
When creating a new series of batteries for electric vehicles (EVs), a leading battery producer approached Boyd to design new liquid cold plates for the battery packs. The new battery packs would be featured in large electric specialty vehicles (such as fire and refuse vehicles) which require extensive amounts of power, leading to strict thermal and weight management requirements.
项目详情
客户：
电动汽车电池制造商
应用：
特种电动汽车电池
技术：
液冷板
行业：
电动汽车
位置：
美国
EV 电池冷却挑战
客户在最初的电池组开发中发现了几个挑战。虽然他们拥有为电动工具和室内多功能车制造小型电池的经验，但正在过渡到为大型特种电动汽车制造电池组。
The specialty vehicle power demand required new, larger battery pack designs for each EV model which resulted in high heat loads. To ensure that the larger battery packs remained cool enough for operation throughout the vehicle’s lifespan, the customer needed custom liquid cold plates (LCPs) designed specifically for this application. Each battery would also need a high-performing TIM (Thermal Interface Material) to contact the battery heat source and minimize heat loss during transfer to the liquid cold plates and liquid cooling system.
Initially, weight was not seen as a big design concern, given the already large size of the battery packs and the complete specialty vehicle. However, throughout evaluation and testing, concerns grew regarding the size of the LCPs potentially affecting battery range. To ensure the added LCP weight minimally affected battery range, it also became crucial for the cold plates to be as compact and light weight as possible.
Boyd的EV液体冷板解决方案
工作开始于Boyd的专用设计中心之一，对每个新的电池组尺寸进行了广泛的热分析，以确定项目的准确、最佳的热需求。一旦这些参数被定义，Boyd提出了几个不同的过去冷板的例子，已经成功地实施到电动汽车电池具有类似的要求。还介绍了若干台电煤层，每个都具有不同的热性能。
在评估了各种选择后，Boyd 的工程师和客户共同决定，采用纤维增强热垫的铝制液体冷板将是最佳解决方案。Boyd的设计中心工程师立即开始根据每个电池组的需求开发图纸。虽然初始设计在处理热管理要求方面很有效，但冷板相对较大，电池的额外重量成为问题。
Boyd leveraged its extensive experience with cold plate construction and began working on ways to cut down weight. After some experimentation, Boyd engineers significantly lowered battery cold plate weight by optimizing the size and shape of each cold plate for each individual battery. The new construction effectively cooled the extreme battery pack heat while reducing the overall weight by 40% from the initial design.
设计完成后，Boyd的原型设计团队迅速开始制作盖章和 CAB 吹牛冷板原型进行评估。
特种车电池液体冷板结果
原型在电池组内进行了广泛的测试，并证明在消除电池热量方面非常有效。最终，高效轻质的液体冷板能够显着提高热性能，同时将电池组的整体重量减轻 40% 以上。 电池将实施到一系列新的电动特种车辆，该项目的成功带来了其他热的机会与客户。
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