Safe cooling

To keep the lithium-ion batteries in hybrid or electric cars and their charging stations within the optimal temperature range, efficient thermal management is required. The ideal solution for this is based on water cooling. Maximum safety, also for batteries in industrially used energy storage systems, is ensured by a tight system made of plastic: flexible as well as robust pipes and connectors from Fränkische Industrial Pipes (FIP), for example, equipped with sensors, keep batteries and components in the optimal temperature range.

The power density of lithium-ion batteries is constantly increasing and at the same time shorter charging times for electric and hybrid cars are becoming more important. However, fast charging processes generate a large amount of heat loss, which has a negative impact on the temperature and the functionality of the complete system. Therefore, efficient thermal management is necessary that cools the entire thermal circuit: for example, converters and radiators in electrically powered cars, but also the cable and charging system with reservoirs, pumps and heaters in charging stations.

Liquid cooling is becoming increasingly interesting for this purpose: Compared to air, water has a higher cooling capacity, can be designed in a more space-saving way and distributes the heat evenly. A battery - whether for vehicles, trucks, buses or energy storage systems - can be tempered directly at the cooling plate and connected to the entire liquid cooling cycle.

Coordinated system solutions in demand

"For liquid cooling in charging stations and e-cars, but also for servers and energy storage systems in industry, the components play an essential role. Our solutions cover all standard applications and can be customised - this is how we design systems for industry and mobility of the future," explains Alexander Wey, Manager Product Unit Industrial Thermal at Fränkische Industrial Pipes.

Since there is often only very limited installation space available for thermal management, for example in charging columns, the flexible and yet mechanically resilient corrugated and smooth pipes made of Fipcool plastic are ideally suited. They enable high flow rates and withstand operating pressures of up to ten bar. FIP offers the pipe dimensions commonly used in water-cooled systems from nominal diameter eight to 37, but also customised solutions.

Connectors with special functions and intelligent connector systems

Since absolute tightness is required for safety reasons in the water cooling of charging stations for electric vehicles, for example, another focus is on the pipe connection. Connectors made of plastic allow the pipe systems in thermal applications to be connected easily and quickly. The space-optimised Fipcool SC quick connectors are temperature-resistant, designed for a long service life and have a large inner diameter in the connection area for a better flow rate. With additional functions such as sensors or anti-rotation devices, the standard solutions meet individual needs. For example, in exceptional cases, dry disconnect connectors (shut-off) are used, which enable drip-free maintenance with their "dripless function".

Individual thermal management system from a single source

Under the name Fipcool Control, the thermal management expert offers connector systems with integrated sensor technology and cable connections. This allows the fluid temperature in the pipe system to be automatically monitored and controlled. Compact design and long service life: with connection elements from the Fipcool Connect range in various dimensions and shapes - whether T and Y distributors or passthroughs - cooling concepts can be customised. Also in the range are the securely lockable Fipcool FIX fixing elements for attaching tubes in various ways. Flexible protective hoses and mats from the Fipcool Protect series protect lines or cables from mechanical and chemical influences, moisture, extreme temperatures, abrasion and impact.

Special solutions for liquid cooling in automobiles

FIP also offers a flexible plastic cooling system for battery and hybrid vehicles that protects the battery packs and the electric motor from temperature fluctuations. Compared to rubber or metal components, it convinces with its higher performance in terms of impact and bending strength. In addition, the customised system is easy to install, saves weight, is flow-optimised and prevents corrosion. Tailored to customer requirements, individual designs are created from corrugated and smooth tube systems, connectors optimised for installation space, blow-moulded connecting elements as well as connector systems with integrated sensors.

Water cooling is particularly suitable for applications with a high energy storage requirement such as charging stations, electrically powered vehicles, server solutions and industrial applications. FIP offers reliable complete systems from a single source - both as a standard programme and as customised special solutions.