Dana Holding Corporation has developed a Long heat exchanger designed to extend battery life in hybrid and electric vehicles. The technology recently made its debut on Tesla Motors’ 2010 all-electric Roadster Sport.
Lithium-ion battery life is dependent on maintaining optimum operating temperatures. Dana’s heat-exchange technology cools the Roadster’s battery by transferring heat generated within the battery to the vehicle’s climate-control system. In addition, a temperature sensor mount provides continuous feedback to the climate-control system. This interface helps to maintain the battery’s ideal temperature during operation, thus helping to extend battery life.
Dana engineers constructed the heat exchanger using a patented aluminum brazing process, ensuring cleanliness of both the climate control and battery coolant fluids. The use of high-strength aluminum alloys provides greater material strength and contributes to weight savings.
Additionally, the chiller’s compact design also provides significant space savings—critical for helping engineers accommodate the Roadster’s 6,800-cell battery pack.
Dana developed and is manufacturing the heat exchanger at its advanced engineering center in Oakville, Ontario, Canada.