GCoreLab Thermal Solution for Electric Vehicle

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

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GCoreLab Thermal Solution for Electric Vehicle

  1. 2. Lithium ion battery <ul><li>Advantages </li></ul><ul><ul><li>Impressive energy density </li></ul></ul><ul><ul><li>Good power density </li></ul></ul><ul><ul><li>Good charge/discharge efficiency </li></ul></ul><ul><ul><li>Long lifespan </li></ul></ul><ul><ul><li>No environmental issues </li></ul></ul><ul><li>However, lithium ion battery is sensitive to temperature and could be a risk to fire safety. </li></ul>The dominant EV battery
  2. 3. <ul><li>High temperatures can be a result of: </li></ul><ul><li>Ambient temperature </li></ul><ul><li>Fast charging </li></ul><ul><li>Drawing large amount of energy from batteries </li></ul>Lithium ion battery Temperature problems
  3. 4. 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
  4. 5. <ul><li>Batteries make up about 70% of the cost of an electric vehicle </li></ul><ul><li>Good thermal management can enable longer lifespan, lower costs and improve safety for EV batteries </li></ul>Thermal Management Critical for EV batteries
  5. 6. <ul><li>GCoreLab’s Liquid Cooling </li></ul><ul><li>Battery capacity of 80% for more than 9years </li></ul><ul><li>Increased lifespan of 2years compared to Air Cooling </li></ul>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
  6. 7. Chevrolet Volt Ford Focus Smart fortwo ED Tesla Roadster Liquid Cooling Technology Current Users
  7. 8. <ul><li>Requirements of the thermal system: </li></ul><ul><ul><li>Temperature (15 -4 0 °C) </li></ul></ul><ul><ul><li>Small temperature range within different battery cells </li></ul></ul><ul><ul><li>Insulation between battery cells </li></ul></ul><ul><ul><li>No leakage </li></ul></ul><ul><ul><li>Light weight (<200kg) </li></ul></ul><ul><ul><li>Low cost (5-10% of battery cost) </li></ul></ul>Case Study Thermal Management for Electric Bus
  8. 9. 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
  9. 10. <ul><li>GCoreLab’s Approach </li></ul><ul><li>No leakage </li></ul><ul><li>- Vacuum brazing </li></ul><ul><li>- Liquid cold plate under battery packs </li></ul><ul><li>- Pipe connections outside battery box </li></ul><ul><li>5. Light weight </li></ul><ul><li>- Liquid cold plates made out of aluminium or high thermal conductivity plastics </li></ul><ul><li>- Sharing of liquid cold plates amongst individual cells instead of dedicated plates </li></ul><ul><li>- Smaller pumps due to lower pressure drops across plates </li></ul><ul><li>6. Low cost </li></ul><ul><li>- Lower maintenance cost due to smaller pump and lower pressures involved </li></ul><ul><li>- Usage of plastic materials instead of the more costly metals </li></ul>Case Study Thermal Management for Electric Bus
  10. 11. <ul><li>Jacket of minichannels using oblique fins around the battery pack </li></ul><ul><li>Thin profile to slot between gaps of the individual cells </li></ul>Incorporation in Battery Packs GCoreLab Thermal Solution
  11. 12. <ul><li>Combined system to cool multiple heat generating devices such as motor controllers, ultra-capacitors and motors </li></ul><ul><ul><li>Better performance in components </li></ul></ul><ul><ul><li>More compact </li></ul></ul><ul><ul><li>Lower cost </li></ul></ul><ul><ul><li>less equipment </li></ul></ul><ul><ul><li>Less weight </li></ul></ul>Incorporation in Automobile GCoreLab Thermal Solution
  12. 13. <ul><li>High performance thermal management </li></ul><ul><ul><li>Higher efficiency, recoverable power and capacity </li></ul></ul><ul><ul><li>Longer battery life/better reliability </li></ul></ul><ul><ul><li>Allows fast charging </li></ul></ul><ul><ul><li>Prevents thermal runaway </li></ul></ul><ul><ul><li>Compact system </li></ul></ul><ul><li>Customizable thermal management to incorporate with existing battery packs and components </li></ul>Conclusion
  13. 14. <ul><li>Thank you! </li></ul>

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