Composite cooling system will increase Tesla Model S range by 23%

The principle of operation of composite materials developed by researchers is based on a natural method

heat dissipation to the vascular system.The engineers used proprietary design technology to create a cooling system that would work as part of the battery's structural packaging. The researchers note that companies such as Tesla, Volvo and Volkswagen are testing it.

Cooling System Design Systemdescribed by scientists in an article published in the journal Composites Part B: Engineering. The technology helps to select the best pattern, size and number of microvascular channels to quickly remove heat from the batteries, as well as optimize the design for efficient coolant flow through the channels.

“These composites act as a heat sink incar with an internal combustion engine. The coolant draws in heat and removes it from the battery composite as it travels through the network of microchannels,” said EurekAlert! Ahmad Najafi, one of the authors of the study.

Image: Drexel University

In the process of structural optimization of the batteryengineers consider several design parameters, such as the thickness and direction of the fibers in each carbon fiber layer, the volume fraction of fibers in the active materials, and the number of microvascular composite panels required for thermal management.

For each combination, researchers measurethe stiffness of each structural composite laminate cooling the battery to ensure they meet vehicle structural integrity standards. They then simulate the vehicle's energy consumption at various speeds over a period of several minutes, while recording battery temperature and predicted vehicle range.

The researchers note that the placementstructural batteries between layers of cooling microvascular composites can stabilize their temperature during use and increase the time and power range in which they operate. Simulations carried out for the Tesla Model S showed a 23% increase in the range of this electric vehicle with the new cooling system.

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