Advancements in Liquid Cold Plates & Liquid
Cooling Systems for eMobility Applications
Liquid Cooling for Electric Vehicles
www.boydcorp.com
July 2020
Liquid Cooling Solutions in Electric Vehicles:
Creating Competitive Advantage in eMobility Applications
Overview
This paper addresses current and upcoming trends and thermal management design challenges for Electric
Vehicles and eMobility with a specific focus on battery and inverter cooling. Liquid Cooling is extremely efficient
to handle higher heat loads, but systems must be designed to optimize size, weight, performance, reliability,
and durability. Through advanced design and technology integration, Aavid, Thermal Division of Boyd
Corporation is working with designers to accomplish these goals in a way that meets current requirements,
enables next generation innovation, and contributes to overall vehicle performance and driver satisfaction. This
article will aid engineers in understanding the role of liquid cooling to improve system development and foster
design creativity.
CURRENT ELECTRIC VEHICLE MARKET TRENDS
The Transportation market is currently undergoing a
significant, fundamental transformation towards
eMobility. Global trends ranging from environmental
awareness, historical gas crises, and urbanization
combined with customer demands for greater
connectivity, safer driving, maximum efficiency,
sustainability and cost savings have culminated in the
exponential growth in demand for and use of Electric
Vehicles (EVs).
The global electronic fleet has risen dramatically over
the last decade; by 2019 there were an estimated 5.6
million electric vehicles on the road with market experts
estimating that more than half of new cars will be
electric by 2040.
Concerns the previously limited electric vehicle adoption
have been addressed, such as battery costs, safety,
reliability, charging station availability, and technology
limitations. Currently, batteries charge faster, power is
Electric vehicles are becoming more prevalent worldwide.
Advancements in Liquid Cold Plates & Liquid
Cooling Systems for eMobility Applications
Liquid Cooling for Electric Vehicles
www.boydcorp.com
July 2020
more efficiently converted and electronics’ speed, complexity, connectivity and processing power increase. However, a
new barrier to market scalability and growth is created as a by-product: more heat.
Advancements including longer lasting, higher performing batteries, greater
connectivity, more accurate and connected sensors, enhanced system
monitoring, faster charging, and improved cabin features are producing
much higher heat loads. In addition to this enhanced performance and
functionality, Manufacturers are demanding smaller, lighter form factors.
The excess heat generated by so much power in such a compact form can
easily lead to system failures and threats to passenger safety if not
managed efficiently and effectively.
Each EV generation has gotten lighter, safer, more reliable and better
connected, and will continue to do so for each new model to come. It will
be imperative that cooling solutions progress ahead of vehicle innovation
for each new advancement to test and prove safety and reliability.
Boyd Corporation and its Thermal Division, Aavid, have aligned closely with
key eMobility innovators and design teams over the past two decades to ensure that our thermal management solutions
exceed industry advancements to empower future innovation. This close collaboration has enabled Boyd engineers to
anticipate upcoming market changes, industry trends and evolving design requirements to influence our research and
development, guide technology roadmaps, and start development early for improved thermal solutions and system
integration. This practice not only leads to more optimized, cost efficient cooling with greater reliability, but also faster
time to market, lower overall costs, and a significant competitive advantage to OEMs.
SOLVING KEY CHALLENGES IN EMOBILITY COOLING
OVERALL ENVIRONMENTAL & USE CONSIDERATIONS
There are several critical considerations surrounding all thermal
management systems within electric vehicles, one of the most significant
being environmental conditions. Vehicles must be able to operate with
guaranteed performance, safety and reliability in conditions with varying
temperature extremes, humidity levels, precipitation, exposure to sand,
saltwater and other environmental factors. Vehicles may also be subjected
to rugged terrain, extreme shock and vibration, collision impact,
electromagnetic interference from advanced electronic systems and many
other factors. Critical components and systems must be designed to
protect against known possible hazards while still being serviceable, easily
maintained and cost efficient.
Inside an electric vehicle:
Compact, High performing systems
Vehicles must run effectively in harsh conditions.