The BOYD Specialty Vehicle Battery Liquid Cold Plate Increases Thermal Performance While Decreasing the Weight of the Battery Pack by over 40%
Project Details
Customer: Electric Vehicle Battery Manufacturer
Application: Specialty Electric Vehicle Batteries
Technology: liquid cold plates
Industry: eMobility
Location: United States
Introduction
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.
EV Battery Cooling Challenge
The customer discovered several challenges during initial battery pack development. While experienced in creating smaller batteries for power tools and indoor utility vehicles, they were transitioning to creating battery packs for large, specialty EVs.
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’s EV Liquid Cold Plate Solution
Work began in one of Boyd’s dedicated design centers, where an extensive thermal analysis was performed on each of the new battery pack sizes to define the exact, optimal thermal requirements for the project. Once these parameters were defined, Boyd presented several different past cold plate examples that had been successfully implemented into electric vehicle batteries with similar requirements. Several TIMs were also presented, each featuring different thermal properties.
After evaluating options, Boyd’s engineers and the customer collaboratively decided that an aluminum liquid cold plate featuring a fiber-reinforced thermal pad would be the optimal solution. Boyd’s design center engineers immediately began developing drawings based on each individual battery pack’s needs. While initial designs were effective in handling the thermal management requirements, the cold plates were relatively large, and the additional weight on the battery became a concern.
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.
Once a design was finalized, Boyd’s prototyping team quickly began creating stamped and CAB brazed cold plate prototypes for evaluation.
Specialty Vehicle Battery Liquid Cold Plate Results
The prototypes were extensively tested within the battery packs and proven to be highly effective at removing heat from the batteries. Ultimately, the highly-efficient and lightweight liquid cold plates were able to dramatically increase thermal performance while decreasing the overall weight of the battery pack by over 40%. The batteries will be implemented into a line of new electric specialty vehicles, and the success of the project has led to other thermal opportunities with the customer.
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本文由莫子若转载自BOYD Official Website，原文标题为:Electric Vehicle Liquid Cold Plate，本站所有转载文章系出于传递更多信息之目的，且明确注明来源，不希望被转载的媒体或个人可与我们联系，我们将立即进行删除处理。
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目录- General Information Board Mounted Heat Sinks part number Introduction Interface Materials Labor Saving Heat Sink to Board and Semiconductor Mounts Clips Accessories
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BOYD（宝德）热界面材料选型指南
描述- Thermal Interface Materials (TIMs) are a critical portion to any effective thermal management system as they transfer heat between solid surfaces. Boyd provides a full array of thermal interface materials, from soft materials like gap fillers, phase change materials, and thermal grease to less compliant materials like thermal rubber pads, films, and thermally conductive hardware.
型号- BCTIM-215-1061,BCTIM-215-1064,BCTIM-215-1063,BCTIM-215-1057,BCTIM-215-1058,BCTIM-215-1059,BCTIM-219-1070,THER-O-BOND 1600,BCTIM-211-1014,BC,BCTIM-211-1018,BCTIM-211-1017,BCTIM-240-1000,BCTIM-211-1016,BCTIM-211-1015,BCTIM-240-1005,BCTIM-211-1019,BCTIM-240-1006,BCTIM-213-1068,BCTIM-213-1069,BCTIM-213-1066,BCTIM-213-1067,BCTIM-216-1041,BCTIM-219-1061,BCTIM-214-1030,BCTIM-219-1060,BCTIM-219-1063,BCTIM-219-1062,BCTIM-219-1064,BCTIM-214-1028,BCTIM-212-1073,BCTIM-214-1029,BCTIM-219-1056,BCTIM-219-1059,BCTIM-230-1021,BCTIM-219-1050,BCTIM-219-1051,BCTIM-218-1047,BCTIM-218-1044,BCTIM-218-1046,BCTIM-218-1045,BCTIM-230-1018,BCTIM-230-1019,BCTIM-230-1016,BCTIM-210-1062,BCTIM-219-1049,BCTIM-219-1048,BCTIM-216-1039,BCTIM-216-1038,BCTIM-210-1078,BCTIM-210-1079,BCTIM-210-1076,BCTIM-210-1077,BCTIM-220-1057,BCTIM-210-1074,BCTIM-210-1075,BCTIM-220-1059,BCTIM-216-1037,BCTIM-216-1036,BCTIM-220-1054,BCTIM-216-1035,BCTIM-220-1055,BCTIM-217-1041,BCTIM-220-1056,BCTIM-217-1042,BCTIM-217-1043,BCTIM-210-1009,BCTIM-212-1020,BCTIM-212-1021,BCTIM-210-1007,BCTIM-212-1022,BCTIM-210-1008,BCTIM-210-1005,BCTIM-220-1060,BCTIM-210-1006,BCTIM-220-1061,BCTIM-210-1003,BCTIM-220-1062,BCTIM-210-1004,BCTIM-220-1063,BCTIM-213-1024,BCTIM-210-1001,BCTIM-213-1025,BCTIM-210-1002,BCTIM-213-1026,BCTIM-213-1027,BCTIM-213-1023,BCTIM-210-1081,BCTIM-220-1064,BCTIM-210-1082,BCTIM-220-1065,BCTIM-220-1066,BCTIM-210-1080,BCTIM-212-1023,BCTIM-212-1025,BCTIM-212-1026,BCTIM-212-1027,BCTIM-212-1028,BCTIM-212-1029,BCTIM-212-1030,BCTIM-212-1031,BCTIM-220-1072,BCTIM-215-1033,BCTIM-215-1031,BCTIM-215-1032,BCTIM-210-1010,BCTIM-217-1060,THER-O-BOND 1500,BCTIM-214-1065
热管理和工程材料解决方案
描述- Boyd公司提供全面的芯片冷却解决方案，包括热沉、热管、液体冷却系统和空气冷却系统。其产品涵盖从标准板级解决方案到集成系统，旨在优化芯片冷却，提高性能和效率。公司拥有丰富的热管理经验和设计专业知识，提供定制化解决方案以满足不同应用需求。
变温™ 热管理产品由一家公司提供，多种解决方案
描述- Boyd公司提供多种热管理解决方案，包括热导粘合剂、散热片和热界面材料（TIMs），应用于汽车、移动计算、企业电子、照明和混合/电动汽车等多个领域。公司拥有热分析实验室，提供技术材料和设计专业知识，以及世界级的制造质量和供应链管理，以解决客户的热管理挑战。资料中详细介绍了多种热管理产品的性能参数和测试方法。
型号- BCTIM-218-1047,BCTIM-218-1044,BCTIM-218-1046,BCTIM-218-1045,BCTIM-219-1049,BCTIM-219-1048,BCTIM-216-1039,BCTIM-216-1038,BCTIM-216-1037,BCTIM-216-1036,BCTIM-220-1054,BCTIM-216-1035,BCTIM-217-1041,BCTIM-217-1042,BCTIM-217-1043,BCTIM-211-1014,BCTIM-210-1009,BCTIM-211-1018,BCTIM-211-1017,BCTIM-212-1020,BCTIM-210-1007,BCTIM-211-1016,BCTIM-212-1021,BCTIM-210-1008,BCTIM-211-1015,BCTIM-212-1022,BCTIM-210-1005,BCTIM-210-1006,BCTIM-210-1003,BCTIM-210-1004,BCTIM-211-1019,BCTIM-210-1001,BCTIM-213-1024,BCTIM-210-1002,BCTIM-213-1025,BCTIM-213-1026,BCTIM-213-1027,BCTIM-213-1023,BCTIM-214-1030,BCTIM-216-1040,BCTIM-214-1028,BCTIM-214-1029,BCTIM-215-1033,BCTIM-215-1034,BCTIM-210-1012,BCTIM-215-1031,BCTIM-210-1013,BCTIM-215-1032,BCTIM-210-1010,BCTIM-210-1011,BC-TIM-219-1052,BCTIM-219-1050,BCTIM-219-1051,BCTIM-219-1053
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