Cooling Plate for EV Battery Pack

Cooling systems for Electric Vehicle (EV) battery packs are crucial for maintaining optimal operating temperatures and extending the lifespan of the battery. Overheating can lead to performance degradation, reduced efficiency, and even damage to the battery cells. Cooling plates are one of the methods used for this purpose.

What are Cooling Plates?

Cooling plates are components within the battery pack that help to dissipate heat generated during charging and discharging cycles. They are usually made of thermally conductive materials like aluminum or copper, efficiently transferring heat away from the battery cells.

Types of Cooling Plates:

Direct Liquid Cooling Plates:

In this design, cooling plates have channels through which a coolant (usually a mix of water and glycol) flows. This coolant absorbs heat from the battery cells and carries it to a heat exchanger outside the battery pack.

Direct liquid cooling is efficient and controls the battery's temperature precisely. However, it adds complexity and weight to the system.

Indirect Liquid Cooling Plates:

Here, the cooling plates have channels for a coolant, but they are separated from the battery cells by a layer of thermally conductive material (like graphite or aluminum foam).

The heat from the battery cells transfers through this material to the coolant in the channels.

This method offers good thermal management while reducing the risk of coolant leaking into the battery.

Phase Change Material (PCM) Cooling Plates:

These plates use materials that change phase (like from solid to liquid) as they absorb heat.

When the battery pack heats up, the phase change material absorbs the heat, preventing the battery from exceeding safe temperature limits.

PCM cooling plates are passive systems, meaning they don't require pumps or additional energy to function.

Air-Cooled Plates:

Some systems use air channels within the cooling plates to allow for natural convection or forced air cooling (with fans).

While simpler and lighter than liquid-cooled systems, air-cooled plates may not be as effective in managing high heat loads.