German automotive supplier Mahle has introduced a groundbreaking battery cooling plate that it heralds as a significant stride in technology advancement. Drawing inspiration from nature, Mahle’s engineers have crafted a bionic structure for the cooling channels, facilitating a novel flow of coolant.
According to Mahle, this innovative approach markedly enhances both the thermodynamic performance and structural-mechanical attributes of the cooling plate. The outcome of this engineering feat is a 10% surge in cooling capacity and a substantial 20% decrease in pressure loss.
The pivotal role of maintaining optimal battery temperatures, especially during demanding scenarios like rapid charging, cannot be overstated. In lithium batteries, it’s crucial to ensure that cell temperatures do not surpass 40 degrees Celsius. Simultaneously, maintaining uniform temperature distribution across all battery cells is imperative, and this is precisely where flow-through plates come into play.
Mahle’s fresh design introduces a dynamic that adjusts the coolant flow rate as per the requirement. Particularly effective for minor temperature differentials between the battery cells and the coolant, this approach enhances heat transfer through controlled flow rates. Mahle’s assertion that their bionic battery cooling plate can curtail the temperature range by up to 50% while significantly reducing peak temperatures showcases its remarkable efficiency. This efficiency, in turn, translates to safer rapid charging, extended battery life, and heightened overall performance.
In addition to the performance enhancements, Mahle underscores the design benefits brought about by the bionic structure. Drawing cues from natural formations like corals, the engineers have achieved greater structural integrity, allowing for the use of thinner materials in manufacturing processes. This not only promotes energy efficiency but also contributes to sustainability efforts.
Dr. Uli Christian Blessing, Head of Global Development Thermal Management at Mahle, expressed his enthusiasm for this leap in innovation, stating, “With our new battery cooling plate, we are diverging from conventional technical geometries and embracing natural structures, such as the coral shape—with outstanding implications for our cooling technology and substantial advantages in structural stability.”
Automotive enthusiasts and industry stakeholders can anticipate the unveiling of Mahle’s pioneering bionic battery cooling plate at the IAA Mobility event in Munich in September 2023.
