Biomimicry takes inspiration from nature. It examines the structures, processes, and designs that animals and plants have developed throughout evolution and applies them to technology.
Engineers at MAHLE have now developed a bionic structure for cooling channels, inspired by nature. This structure allows for a different flow of cooling fluid, significantly enhancing the performance and characteristics of the cooling plate.
You might think that technology in and around automobiles has already been pushed to its limits. Think again. MAHLE has made a true technological leap in the cooling of high-voltage batteries: 10 percent more cooling capacity and a 20 percent lower pressure loss are quite impressive figures. The advantages are substantial: The battery can reliably maintain the necessary temperature range, both while driving and during charging. This means more power and shorter charging times. Additionally, battery life is extended.
"With our new battery cooling plate, we move away from technical geometries and instead utilize natural structures, such as the coral-like pattern, with outstanding effects on our cooling technology and structural stability," said Dr. Uli Christian Blessing, Head of Global Development Thermomanagement at MAHLE.
MAHLE is one of the pioneers in cooling lithium-ion batteries, from compact cars to large commercial vehicles. Batteries are highly temperature-sensitive, and the cell temperature should not exceed 40 degrees Celsius for extended periods. Simultaneously, temperature distribution across all cells should be as uniform as possible. Therefore, batteries are typically cooled using plates with flowing coolant. In MAHLE's new development, the flow rate of the coolant can be adjusted to meet the actual cooling requirements. When the temperature difference between battery cells and coolant is minimal, a higher flow rate enhances heat transfer. The bionic battery cooling plate from MAHLE is so efficient that it reduces the temperature range by 50 percent, particularly lowering peak temperatures. This significantly contributes to the longevity and performance of the expensive battery.
Furthermore, MAHLE has reduced the material usage for the bionic plate by up to 15 percent, saving 15 percent in CO2 emissions compared to conventionally flowed plates.
In terms of design, the bionic structure also offers advantages. Increased stiffness allows for the use of thinner material, further improving its effectiveness.
Additionally, there is more flexibility to enable new manufacturing processes with lower energy and material consumption. A contribution to sustainability.