Germany’s MAHLE Introduces Bionic Cooling Plate for Improved Battery Efficiency

Top 5 Reasons Why Solid State batteries Are Just Around The Corner

Drawing inspiration from the natural world, Germany-based automotive supplier MAHLE has achieved technological advancement through its novel battery cooling plate. By adopting a bionic design for the cooling channels, which mimics nature’s patterns, the company’s engineers have brought about a noteworthy transformation. This innovative approach leads to a enhancement of both thermodynamic efficiency and structural-mechanical characteristics of the cooling plate. Consequently, MAHLE succeeded in elevating cooling performance by 10 per cent while simultaneously curbing pressure loss by an impressive 20 per cent.

The advancement helps keep the battery within the safe temperature range, rendering it more efficient and able to charge faster. In addition, its service life is increased. On top of this, MAHLE notes that it has reduced the amount of material used for the plate by up to 15 per cent, thus saving that much CO2. 

“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,” said Dr Uli Christian Blessing, head of global development thermal management at MAHLE.

Lithium-ion batteries exhibit high sensitivity to temperature variations, necessitating strict control. Even when subjected to demanding conditions like rapid charging, the cell temperature should not surpass 40 degrees Celsius for extended periods. Achieving a uniform temperature distribution across all cells is equally crucial. To achieve this, flow-through plates are commonly employed for battery cooling.

MAHLE’s latest innovation introduces an adaptive approach to coolant flow, tailoring it based on the prevailing requirements. Particularly when faced with minor temperature disparities between battery cells and coolant, enhancing heat transfer is achieved through accelerated flow rates. The revolutionary bionic battery cooling plate from MAHLE demonstrates exceptional efficiency, resulting in a remarkable 50 per cent reduction in the temperature range. Further, it substantially diminishes peak temperatures, the firm notes. This advancement significantly enhances both the longevity and performance of the costly battery, signifying a noteworthy contribution by the Group.

Furthermore, the bionic structure also presents aesthetic advantages. Increased structural integrity enables the utilization of thinner materials in the battery cooling plate, amplifying its effectiveness. Moreover, the design offers greater flexibility, facilitating novel manufacturing processes that demand less energy and raw materials. 

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 September 4 to 10, 2023. 

For well over a decade, MAHLE has been developing systems for cooling lithium-ion batteries for small cars to large commercial vehicles. 

Recently, Taiwanese solid-state battery manufacturer ProLogium and MAHLE signed an MOU for the development of the first thermal management system tailored for ProLogium’s next-generation solid-state batteries.