DuPont Mobility & Materials has launched a new eCool technology for cooling high-pressure battery packs internally and externally with multi-layer cooling lines. This solution addresses the challenges associated with increased cooling line requirements in xEVs, which are directly related to the need to manage heat and energy to maximize battery performance, safety, and longevity.
"Automotive coolant lines are crucial for maintaining the performance of electric vehicle batteries. As a major application, they represent an important target for improving sustainability. Our eCool solution provides the industry with a high-performance, flexible, and more sustainable solution, while also offering cost-effectiveness," explains Laurent Lefebvre, Global Automotive Market Director, DuPont Mobility & Materials.
The cooling tubing length required for electric vehicles may be three times that of a conventional internal combustion engine system. For these large components, engineers face the challenge of finding a more sustainable solution that can also withstand the stresses of the cooling fluid. DuPont's eCool technology, based on the co-extrusion of Zytel LCPA long-chain polyamide with thermoplastic olefin elastomer, offers an attractive alternative to currently heavier options such as thick EPDM rubber hoses and other thermoplastic components.
The eCool solution not only reduces weight but also provides better resistance to various automotive coolants while maintaining cost competitiveness. Furthermore, DuPont's evaluation indicates that the eCool solution can significantly reduce the global warming potential (GWP) of these cooling tubes by more than half compared to single-layer PA12 tubes.
This new eCool technology can be easily processed through extrusion and hot-forming, and provides:
● Lightweight. Lighter than thicker EPDM rubber pipes reinforced with textiles.
● Sustainability: Possesses a lower Global Warming Potential (GWP) compared to some alternative flexible polyamides, contributing to reduced environmental impact.
● Resistant to coolants/hydrolytic agents. Exhibits both barrier and stress-resistance properties against the chemical components of coolants and hydrolytic agents.
● Customizable solutions available at the DuPont Automotive Electrification Excellence Center for testing and customization.
● Cost-effectiveness. Providing a cost-effective solution for the cooling lines of electric vehicles.
● Flexible design. The position of the thermoplastic olefin elastomer layer can be customized to enhance the flexibility of the pipe/pipeline.
DuPont provides production-level support for eCool technology at its facilities in Geneva and other application development centers worldwide. This includes advanced CAE/FEA simulation, compression testing, post-processing support, welding, and explosive pressure testing, as well as mechanical property evaluations before and after air and chemical aging, salt stress cracking, cold impact, and bending tests. With its industrial-scale processing equipment, DuPont enables customers to manufacture cooling lines under near-commercial conditions, followed by testing to determine the optimal processes and post-processing requirements.
The new eCool technology is the latest advancement and solution offered by DuPont for the electrification of automobiles, including:
● DuPont Zytel HTN mixed line shaft for electronic engines
● Plastic/metal composite cooling plates made from DuPont Zytel HTN, used to enhance the durability and thermal management performance of battery units.
● DuPont Zytel and DuPont Crastin Orange stable materials are used for high-pressure terminals and connectors, busbars, switches, and relays.
● DuPont Zytel and Zytel HTN are used in various temperature and humidity conditions for contact with corrosive liquids and loads with low to high voltage.
● DuPont Crastin HR hydrolytically stable PBT, used for switches, connectors, and electronic control devices.