With the transformation of the global energy structure and the improvement of environmental protection awareness, electric vehicles have become an important development direction of the automotive industry. As the "heart" of electric vehicles, the performance and life of batteries directly affect the performance and reliability of the entire vehicle.
In this context, the importance of battery thermal management systems has become increasingly prominent, and liquid cooling technology, as one of the efficient heat dissipation methods, has become one of the key technologies to improve the performance of electric vehicles. It is facing the dual challenges of technological progress and cost control, and has gradually become a research hotspot in the industry.
Liquid cooling technology refers to the circulation of liquid media (such as water, ethylene glycol solution, etc.) to remove the heat generated by the battery, thereby maintaining the battery operating within a suitable temperature range. This technology is particularly important in high-performance electric vehicles because it can effectively extend battery life, improve energy density and charging efficiency.
Compared with traditional air cooling systems, liquid cooling systems have the advantages of higher heat conduction efficiency, smaller size and weight, and lower noise.
The design and manufacture of liquid cooling systems is a comprehensive project that requires engineers to have interdisciplinary knowledge and skills, as well as a deep understanding of new materials, new processes and new technologies. The multiple key technologies involved include but are not limited to:
01 Flow channel design
Flow channel design is the core of the liquid cooling system and directly affects the flow characteristics and heat exchange efficiency of the coolant. By using computational fluid dynamics (CFD) simulation technology, engineers can simulate the flow of coolant in the flow channel and predict and analyze the heat exchange efficiency. Combined with the structural topology optimization method, the optimal flow channel geometry can be found to achieve higher thermal conductivity and lower fluid resistance.
02 Material selection
The choice of materials has a direct impact on the performance of the liquid cooling system. Usually, liquid cooling plates will choose metal materials with high thermal conductivity such as aluminum or copper, which can effectively conduct heat from the heat source and quickly take it away through the coolant. However, in addition to thermal conductivity, the corrosion resistance and mechanical strength of the material are also factors that must be considered in the design. These characteristics ensure that the liquid cooling system can maintain long-term stability and reliability in various working environments.
03 Pump and Radiator
The pump and radiator are the "heart" and "lungs" of the liquid cooling system. Together, they maintain the circulation of the coolant and the dissipation of heat. As the "power source" of the liquid cooling system, the key to the selection of the pump lies in its efficiency and reliability. It needs to ensure that it can provide a stable flow rate under various working conditions. The design of the radiator needs to consider cost-effectiveness while ensuring heat dissipation performance to achieve the best cost-effectiveness.
04 Control Strategy
The control strategy is crucial for the effective operation of the liquid cooling system. Through precise control algorithms, the flow rate of the coolant and the working parameters of the radiator can be dynamically adjusted according to the actual temperature and working state of the heat source, thereby ensuring that the temperature of the battery or other key components is stable within the optimal working range to prevent overheating or overcooling.
05 Manufacturing Process
The advancement of the manufacturing process directly affects the performance and reliability of the liquid cooling system. The use of 3D printing technology and microchannel processing technology can achieve precision manufacturing of liquid cooling plates. These technologies make the size and shape of the flow channel more precise, thereby improving the compactness and heat dissipation efficiency of the entire system. At the same time, advanced manufacturing processes also help reduce manufacturing defects and improve product consistency and reliability.
At present, many high-end electric vehicle brands have begun to adopt liquid cooling systems, such as Porsche and Audi, and Tesla's Model S and Model X use liquid cooling battery systems, which achieve efficient thermal management through cooling plates and coolant circulation systems integrated in the battery pack.
