MAHLE engineers have developed a bio-inspired structure for cooling channels in a battery cooling plate that significantly improves the thermodynamic performance and structural-mechanical properties of the cooling plate. As a result, MAHLE was able to increase cooling performance by 10% and reduce pressure loss by 20%.

The battery can be reliably and homogeneously kept within the necessary temperature window. It thus becomes more efficient and can be charged more quickly. In addition, its service life is increased.

On top of this, MAHLE has reduced the amount of material used for the plate by up to 15%. MAHLE will present its new bionic battery cooling plate to the public for the first time at the IAA Mobility. The automotive trade fair will take place in Munich from 4 to 10 September 2023.

With our new battery cooling plate, we are breaking away from technical geometries and instead using natural structures, such as the coral shape-with outstanding effect for our cooling technology and great advantages in structural stability to boot.

—Dr Uli Christian Blessing, head of global development thermal management at MAHLE

Lithium-ion batteries are very temperature-sensitive. The cell temperature should not exceed 40 ˚C over longer periods—even under extreme conditions such as fast charging. At the same time, the temperature distribution across all cells must be as uniform as possible. The batteries are therefore usually cooled via flow-through plates.

In the latest development from MAHLE, the flow rate of the coolant is controlled according to demand: Especially in the case of small temperature differences between battery cells and coolant, heat transfer is improved by slower flow rates. The bio-inspired battery cooling plate from MAHLE works so efficiently that the temperature range can be reduced by 50% and peak temperatures in particular can be significantly lowered.

The bionic structure also offers design advantages. Greater rigidity makes it possible to use the battery cooling plate with lower material thicknesses. This further improves its effectiveness. In addition, there are more degrees of freedom to enable new manufacturing processes with less energy and material input.