GCoreLab Thermal Solution for Electric Vehicle
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GCoreLab Thermal Solution for Electric Vehicle

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Liquid Cooling for Electric Vehicle/ Hybrid Electric Vehicle Battery: A Case Study

Liquid Cooling for Electric Vehicle/ Hybrid Electric Vehicle Battery: A Case Study

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    GCoreLab Thermal Solution for Electric Vehicle GCoreLab Thermal Solution for Electric Vehicle Presentation Transcript

    •  
    • Lithium ion battery
      • Advantages
        • Impressive energy density
        • Good power density
        • Good charge/discharge efficiency
        • Long lifespan
        • No environmental issues
      • However, lithium ion battery is sensitive to temperature and could be a risk to fire safety.
      The dominant EV battery
      • High temperatures can be a result of:
      • Ambient temperature
      • Fast charging
      • Drawing large amount of energy from batteries
      Lithium ion battery Temperature problems
    • Low temperatures can be a result of: Ambient temperature Temperature gradients can be caused by: Uneven cooling/heating of batteries Lithium ion battery Temperature problems
      • Batteries make up about 70% of the cost of an electric vehicle
      • Good thermal management can enable longer lifespan, lower costs and improve safety for EV batteries
      Thermal Management Critical for EV batteries
      • GCoreLab’s Liquid Cooling
      • Battery capacity of 80% for more than 9years
      • Increased lifespan of 2years compared to Air Cooling
      No Cooling Air Cooling Low resistance cells GCoreLab’s Liquid Cooling Source: NREL – Battery Thermal Modeling and Testing Relative Capacity of Battery vs. Time Thermal Management Critical for EV batteries
    • Chevrolet Volt Ford Focus Smart fortwo ED Tesla Roadster Liquid Cooling Technology Current Users
      • Requirements of the thermal system:
        • Temperature (15 -4 0 °C)
        • Small temperature range within different battery cells
        • Insulation between battery cells
        • No leakage
        • Light weight (<200kg)
        • Low cost (5-10% of battery cost)
      Case Study Thermal Management for Electric Bus
    • GCoreLab’s Approach 1. Temperature (15 -4 0 °C) - Easily achieved with low flow rates for our liquid cooling/heating system - Possibility of routing fluid flow to heat sources or cooler regions in vehicle 2. Small temperature range within different battery cells - Supply of flow to liquid cold plates in a parallel configuration - Uniform cooling of individual cells 3. Insulation between battery cells - Insulative thermal interface material - Overmolding of high thermal conductivity plastics - Liquid cold plates made out of high thermal conductivity plastics Case Study Thermal Management for Electric Bus
      • GCoreLab’s Approach
      • No leakage
      • - Vacuum brazing
      • - Liquid cold plate under battery packs
      • - Pipe connections outside battery box
      • 5. Light weight
      • - Liquid cold plates made out of aluminium or high thermal conductivity plastics
      • - Sharing of liquid cold plates amongst individual cells instead of dedicated plates
      • - Smaller pumps due to lower pressure drops across plates
      • 6. Low cost
      • - Lower maintenance cost due to smaller pump and lower pressures involved
      • - Usage of plastic materials instead of the more costly metals
      Case Study Thermal Management for Electric Bus
      • Jacket of minichannels using oblique fins around the battery pack
      • Thin profile to slot between gaps of the individual cells
      Incorporation in Battery Packs GCoreLab Thermal Solution
      • Combined system to cool multiple heat generating devices such as motor controllers, ultra-capacitors and motors
        • Better performance in components
        • More compact
        • Lower cost
        • less equipment
        • Less weight
      Incorporation in Automobile GCoreLab Thermal Solution
      • High performance thermal management
        • Higher efficiency, recoverable power and capacity
        • Longer battery life/better reliability
        • Allows fast charging
        • Prevents thermal runaway
        • Compact system
      • Customizable thermal management to incorporate with existing battery packs and components
      Conclusion
      • Thank you!