Keeping batteries in electric vehicles at the correct temperature for the vehicle’s optimal operation is still one of the main challenges for battery manufacturers and electrified vehicle manufacturers.
Batteries must operate in a specific temperature range to avoid excessive battery cell wear-off. Battery cooling systems must therefore be able to develop this thermal management correctly in order to avoid loss of vehicle performance. In very hot climates it is necessary to cool and maintain the battery at a specific temperature. When the battery overheats, such as during fast or super-fast charging, this cooling is necessary. The same happens in very cold environments where the battery must be warmed up to the ideal operational temperature to avoid alterations in the battery’s autonomy and performance.
So far, there are two dominant cooling technologies for electrified vehicles. The first one, is channelling air to the batteries to cool them with the air itself, either by the vehicle’s own movement or by generating the air with fans. The other, more efficient and optimal cooling technology is liquid cooling. The cooling solution is pumped through specially designed pipes to reach the batteries, with the aim of keeping them cool at any environmental temperature and reducing degradation to minimum.
Piped liquid cooling systems provide more efficient battery thermal management because they are better at moving heat away from the batteries than air-cooled systems.
When selecting a liquid cooling system, it is essential to consider the impact that the system itself can have on the overall performance of the vehicle. It is important to consider which design is used when selecting fans, water pumps and piping, with the aim of being as efficient as possible. A good choice of cooling system components can reduce the overall energy consumption of an electric vehicle by up to 75%.
At ILPEA Galvarplast we develop pipes for battery cooling systems for electrified vehicles based on quality, the use of sustainable materials and maximising the efficiency of the thermal management system.
We have our own engineering and R&D departments that develop solutions tailored to the technical requirements of our customers. Focusing among other aspects in the physical location of the cooling system in relation to the battery pack inside the EV, not only to minimise the effects of ambient temperature and maximise heat dissipation, but also to avoid excessive mechanical stress on the cooling system due to road vibrations and to reduce wear over the years.
The ILPEA Energy Systems division develops all kinds of fluid handling solutions for the electric vehicle and e-mobility.