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Power Battery Thermal Solution
Power battery cooling solution

Current new energy vehicles are basically powered directly or indirectly by battery packs. According to the energy source and power composition, electric vehicles can be divided into pure electric vehicles (EV, Electric Vehicle) and hybrid electric vehicles (HEV, Hybrid Electric Vehicle) and Fuel Cell Electric Vehicle (FCEV, Fuel Cell Electric Vehicle), no matter which form of new energy vehicle, the thermal management of the battery pack is a very important part of its design.

Physical parameters of lithium batteries



Processing technology introduction
Our battery pack liquid cooling solution mainly uses buried tube and microchannel technology. The buried tube process is to make full use of the high thermal conductivity of copper. We use the method of slotting on the aluminum plate and then embedding the copper tube. The micro-channel method is to increase the convective heat transfer coefficient of the internal flow, and let the coolant take away the heat more quickly and evenly.
1 Buried pipe: one side is attached to the heating device, the copper pipe and the slotted aluminum plate are interference fit, and the copper pipe is flattened and milled to ensure a better fit.

2.Micro-channel: The micro-channel structure is obtained by means of profile mold or machining, and then sealed with welding process, which can fully improve the convective heat transfer coefficient between the internal fluid and the wall, and greatly improve the heat transfer efficiency.


Battery specification (lithium iron phosphate battery)
Battery type: lithium iron phosphate
Rated capacity: 55Ah
Nominal voltage: 3.2V
DC internal resistance: 2mΩ
Battery size: 136mm x 199mm x 28.5mm
Maximum continuous charge current: 3C
Maximum continuous discharge current : 5C

Waterway and battery pack model


Base material: AL6063-T6    Pipe material: copper T2
Using 2 parallel 120 strings, the entire battery system is divided into 4 cooling units, and now one unit is subjected to thermal analysis.
The heat loss of lithium iron phosphate batteries mainly comes from internal resistance and reaction heat. The charging and discharging processes are different, and vary with different SOCs. The loss data of the battery cells of this project is shown in the figure below.

Loss data in charging mode


Loss data in discharge mode


Boundary conditions

Refrigerant: 50% ethylene glycol aqueous solution by volume
Refrigerant temperature: 25℃
Volume flow rate: 4L/min

To Design requirements
Flow resistance is less than 10Kpa
The battery temperature rise is less than 20℃, and the temperature difference between the batteries is less than 5℃

Cloud map of flow field distribution


Cloud map of battery surface temperature distribution during charging