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TR-CY-T029
Trumony
TRCYT029
Heat Exchanger Lithium Ion Battery Cooling System Aluminum Cooling Ribbon
1. Heat Exchanger Lithium Ion Battery Cooling System
In order to meet the long endurance mileage requirements of electric vehicles, the energy density and the number of single cells used in electric vehicles continue to rise, resulting in an increase in the thermal load of the battery packs.
However, due to the limitation of vehicle layout space and vehicle weight, the gap between the cells and the heat dissipation space are reduced,and traditional natural heat dissipation and forced air cooling can no longer meet the cooling needs of batteries under high-rate charge and discharge conditions.
For keeping the temperature of the power lithium battery within an appropriate range and ensuring the safety and service life of the battery system, it is necessary to develop a high-efficiency liquid cooling system. One of the important components in a liquid cooling system is the liquid cooling plate.
Micro-multiport aluminum tube is the high-tech aluminum products under the process of hot extrusion from refined aluminum ingot and then zinc spraying for anti-corrosion.
Micro-multiport tube is the core materials of new generation parallel flow air conditioning heat exchangers. It is outstanding in enviromental-friendly, efficient, energy-saving and cost reduction and was approved vividly in automobile air conditioning system. With restriction and prohibition of the application of the traditional refrigerant, it is a trend that household and commerical air conditioning heat exchanger needs revolution.
2. Comparison of liquid cooling and air cooling
| Media | Volume | Cost | Effect | |
| Free cooling | Heat sink | Big | Low | / |
Air cooling | Fan、radiator、air duct | Bigger | Higher | Better |
| Water cooling | Liquid cooling plate, heat exchanger, heat exchange pump | Small | High | Great |
3. Plate type provided by Trumony
| Process introduction | Features | |
 | 1) Design the flow channel according to the strength and heat exchange requirements. 2) The microchannel flat tubes suitable for the battery pack space are produced by extrusion and drawing technology. 3) Weld single or multiple flat tubes with headers, and then divert the water inlet and outlet through the manifold tubes respectively.(The inlets, outlets and connectors are machined by CNC.) Arrange square cells on flat tubes | 1) The effective heat dissipation area is large under the fixed volume. 2) The mold and processing cost are low. 3) Cold plate strength is better. It is suitable for heat exchange on the side and bottom of the prismatic battery. |
 | ||
 | 1) Stamping to produce runner plates 2) Brazing to fix the runner plate and the base plate to form the flow channel. 3) The inlets and outlets are made by CNC and welded to the base plate. Flat surface for battery arrangement | 1) The mass production cost is low and the production efficiency is high. 2) The flow channel can be more reasonably planned according to the heat source. 3) Suitable for heat exchange at the bottom of square and cylindrical batteries. |
 | 1) Forming the cold pipe flow channel at one time through the extrusion and drawing process. 2) Welding the manifold tubes, inlets, outlets and connectors. Bend the tube to fit the battery | 1) Large side heat exchange area. 2) The best solution for side heat exchange in column cells(18650,21700,46800). |
4. The development content and requirements of the Trumony Battery Pack Liquid Cooling System include:
1) Researching different liquid cooling plate fabrication processes for your project and comparing the advantages, disadvantages, costs and applicability of different liquid cooling forms.
2) Flexibly developing of flow channel design according to your application field, choose a liquid cooling system with stronger applicability and higher heat exchange efficiency, and support of customised cooling/heating rates (e.g. not less than 1°C/min)
3) Developing liquid cooling systems with better temperature uniformity(e.g. the maximum temperature difference between battery packs during cooling is no more than 5°C, and during heating process, the maximum temperature difference of the battery pack does not exceed 8℃)
4) Development of more reliable liquid cooling systems (e.g. pressure resistance of 350kPa or more, service life of 10 years, total flow resistance of in the range of 20-30kPa)
5) Trumony Liquid Cooling Systems with safety guarantees (including leakage risk control, insulation protection, flame retardant requirements, etc.).
5. The Trumony development process
In order to design a battery pack liquid cooling system that meets the development requirements, the specific design process of Trumony includes but is not limited to the following 6 steps:
1) Design inputs (determine the flow rate, battery heating power and the arrangement of modules in the battery pack, etc.);
2) Simulation of the flow, thermal and vibration fields of the liquid-cooled system and correction of the numerical models through simulation results.;
3) Prototyping (machining) of liquid-cooled plates and conducting thermal performance tests and type tests.;
4) Design revision, 2/3 prototypes, thermal performance testing and type testing
5) Structural review of the entire liquid cooling system and risk assessment for mass production;
6) Determine the structure of the liquid cooling system that can be mass-produced.
6. Quality assurance
1. Shipping inspection - 1) Appearance inspection; 2) Size inspection; 3) Normal temperature sealing.
2. Thermal performance test - 1) Cooling performance test; 2) Heating performance test.
3. Type test - 1) Low temperature sealing test; 2) Pressure drop test; 3) Static pressure strength test; 4) Burst test; 5) High and low temperature resistance test; 6) Pressure alternating test; 7) Vibration test ; 8) Salt spray test; 9) Internal corrosion test.
e.g:
Multiport Extruded Aluminum Tube(MPE)- which is used for automobile air conditioner condenser has larger internal section area, better effectiveness for heat transfer. At the same time, has the following properties:
1). Lower energy costs
2). Higher performance
3). Less space and weight
4). High corrosion and pressure resistance
5). High recycling value
6). Pressure drop and silent solution
Through the above liquid cooling system development process, Trumony can design a liquid cooling system that meets the requirements of battery cooling, heating and temperature uniformity.
Heat Exchanger Lithium Ion Battery Cooling System Aluminum Cooling Ribbon
1. Heat Exchanger Lithium Ion Battery Cooling System
In order to meet the long endurance mileage requirements of electric vehicles, the energy density and the number of single cells used in electric vehicles continue to rise, resulting in an increase in the thermal load of the battery packs.
However, due to the limitation of vehicle layout space and vehicle weight, the gap between the cells and the heat dissipation space are reduced,and traditional natural heat dissipation and forced air cooling can no longer meet the cooling needs of batteries under high-rate charge and discharge conditions.
For keeping the temperature of the power lithium battery within an appropriate range and ensuring the safety and service life of the battery system, it is necessary to develop a high-efficiency liquid cooling system. One of the important components in a liquid cooling system is the liquid cooling plate.
Micro-multiport aluminum tube is the high-tech aluminum products under the process of hot extrusion from refined aluminum ingot and then zinc spraying for anti-corrosion.
Micro-multiport tube is the core materials of new generation parallel flow air conditioning heat exchangers. It is outstanding in enviromental-friendly, efficient, energy-saving and cost reduction and was approved vividly in automobile air conditioning system. With restriction and prohibition of the application of the traditional refrigerant, it is a trend that household and commerical air conditioning heat exchanger needs revolution.
2. Comparison of liquid cooling and air cooling
| Media | Volume | Cost | Effect | |
| Free cooling | Heat sink | Big | Low | / |
Air cooling | Fan、radiator、air duct | Bigger | Higher | Better |
| Water cooling | Liquid cooling plate, heat exchanger, heat exchange pump | Small | High | Great |
3. Plate type provided by Trumony
| Process introduction | Features | |
| 1) Design the flow channel according to the strength and heat exchange requirements. 2) The microchannel flat tubes suitable for the battery pack space are produced by extrusion and drawing technology. 3) Weld single or multiple flat tubes with headers, and then divert the water inlet and outlet through the manifold tubes respectively.(The inlets, outlets and connectors are machined by CNC.) Arrange square cells on flat tubes | 1) The effective heat dissipation area is large under the fixed volume. 2) The mold and processing cost are low. 3) Cold plate strength is better. It is suitable for heat exchange on the side and bottom of the prismatic battery. |
| ||
| 1) Stamping to produce runner plates 2) Brazing to fix the runner plate and the base plate to form the flow channel. 3) The inlets and outlets are made by CNC and welded to the base plate. Flat surface for battery arrangement | 1) The mass production cost is low and the production efficiency is high. 2) The flow channel can be more reasonably planned according to the heat source. 3) Suitable for heat exchange at the bottom of square and cylindrical batteries. |
| 1) Forming the cold pipe flow channel at one time through the extrusion and drawing process. 2) Welding the manifold tubes, inlets, outlets and connectors. Bend the tube to fit the battery | 1) Large side heat exchange area. 2) The best solution for side heat exchange in column cells(18650,21700,46800). |
4. The development content and requirements of the Trumony Battery Pack Liquid Cooling System include:
1) Researching different liquid cooling plate fabrication processes for your project and comparing the advantages, disadvantages, costs and applicability of different liquid cooling forms.
2) Flexibly developing of flow channel design according to your application field, choose a liquid cooling system with stronger applicability and higher heat exchange efficiency, and support of customised cooling/heating rates (e.g. not less than 1°C/min)
3) Developing liquid cooling systems with better temperature uniformity(e.g. the maximum temperature difference between battery packs during cooling is no more than 5°C, and during heating process, the maximum temperature difference of the battery pack does not exceed 8℃)
4) Development of more reliable liquid cooling systems (e.g. pressure resistance of 350kPa or more, service life of 10 years, total flow resistance of in the range of 20-30kPa)
5) Trumony Liquid Cooling Systems with safety guarantees (including leakage risk control, insulation protection, flame retardant requirements, etc.).
5. The Trumony development process
In order to design a battery pack liquid cooling system that meets the development requirements, the specific design process of Trumony includes but is not limited to the following 6 steps:
1) Design inputs (determine the flow rate, battery heating power and the arrangement of modules in the battery pack, etc.);
2) Simulation of the flow, thermal and vibration fields of the liquid-cooled system and correction of the numerical models through simulation results.;
3) Prototyping (machining) of liquid-cooled plates and conducting thermal performance tests and type tests.;
4) Design revision, 2/3 prototypes, thermal performance testing and type testing
5) Structural review of the entire liquid cooling system and risk assessment for mass production;
6) Determine the structure of the liquid cooling system that can be mass-produced.
6. Quality assurance
1. Shipping inspection - 1) Appearance inspection; 2) Size inspection; 3) Normal temperature sealing.
2. Thermal performance test - 1) Cooling performance test; 2) Heating performance test.
3. Type test - 1) Low temperature sealing test; 2) Pressure drop test; 3) Static pressure strength test; 4) Burst test; 5) High and low temperature resistance test; 6) Pressure alternating test; 7) Vibration test ; 8) Salt spray test; 9) Internal corrosion test.
e.g:
Multiport Extruded Aluminum Tube(MPE)- which is used for automobile air conditioner condenser has larger internal section area, better effectiveness for heat transfer. At the same time, has the following properties:
1). Lower energy costs
2). Higher performance
3). Less space and weight
4). High corrosion and pressure resistance
5). High recycling value
6). Pressure drop and silent solution
Through the above liquid cooling system development process, Trumony can design a liquid cooling system that meets the requirements of battery cooling, heating and temperature uniformity.
