GCoreLab Thermal Solution for Electric Vehicle
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Transcript of GCoreLab Thermal Solution for Electric Vehicle
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Lithium ion battery
AdvantagesImpressive energy densityGood power densityGood charge/discharge efficiencyLong lifespanNo environmental issues
However, lithium ion battery is sensitive to temperature and could be a risk to fire safety.
The dominant EV battery
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High temperatures can be a result of:1.Ambient temperature2.Fast charging3.Drawing large amount of energy from batteries
Lithium ion batteryTemperature problems
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Low temperatures can be a result of:Ambient temperature
Temperature gradients can be caused by:Uneven cooling/heating of batteries
Lithium ion batteryTemperature problems
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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 ManagementCritical for EV batteries
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No CoolingAir Cooling
Low resistance cells
GCoreLab’s Liquid CoolingGCoreLab’s Liquid Cooling
Source: NREL – Battery Thermal Modeling and Testing
Relative Capacity of Battery vs. Time
GCoreLab’s Liquid Cooling
Battery capacity of 80% for more than 9years
Increased lifespan of 2years compared to Air Cooling
Thermal ManagementCritical for EV batteries
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Chevrolet Volt Ford Focus
Smart fortwo ED Tesla Roadster
Liquid Cooling TechnologyCurrent Users
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Requirements of the thermal system:
1. Temperature (15-40°C)
2. Small temperature range within different battery cells
3. Insulation between battery cells
4. No leakage
5. Light weight (<200kg)
6. Low cost (5-10% of battery cost)
Case StudyThermal Management for Electric Bus
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GCoreLab’s Approach1. Temperature (15-40°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 StudyThermal Management for Electric Bus
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GCoreLab’s Approach4. 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 StudyThermal Management for Electric Bus
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Jacket of minichannels using oblique fins around the battery pack
Thin profile to slot between gaps of the individual cells
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Incorporation in Battery PacksGCoreLab Thermal Solution
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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
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Incorporation in AutomobileGCoreLab Thermal Solution
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Conclusion
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
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Thank you!