Innovative triply periodic minimal surface (TPMS) metamaterials could significantly improve thermal management systems for electric vehicles, researchers claim.
Developing efficient thermal management solutions is more important than ever as electric vehicle (EV) battery packs are increasingly pushed to maximize energy storage. A recent study led by researchers explores the application of triply periodic minimal surfaces (TPMS) within these systems, showing promising results for enhancing thermal dissipation without compromising structural integrity.
The research examines the properties of composite TPMS lattices, particularly their capacity to balance thermal conductivity and mechanical performance. According to the authors, these metamaterials can be fine-tuned through adjustments to material composition and geometric structure, enabling control over distinct properties to meet specific requirements for thermal management.
Using 3D printing techniques, the researchers manufactured copper-plated TPMS primitive lattices. Thermal management relies on cold plates equipped with fluid channels to efficiently dissipate heat from battery components. Initial measurements indicated low pressure drops across these cold plates, which is ideal for fluid flow.
High-performance battery thermal management systems require materials to be compliant enough to accommodate thermal expansion and enable effective heat transfer. The findings revealed various lattice geometries with increased copper thickness, which produced thermally conductive structures without sacrificing mechanical compliance.
"The absence of significant cracks within the internal cells contributed to the high compliance of the structures," the authors stated, emphasizing their discovery's application potential.
Through this study, researchers demonstrated the promising benefits of TPMS structures for thermal management solutions, addressing the growing need for improved battery cooling systems as energy densities soar. The utilization of copper plating enhanced thermal conductivity significantly, with the study recording enhancements of up to 216% at low copper concentrations.
Notably, pressure drop values dropped below 6.5 kPa, showcasing the effectiveness of increasing the number of internal channels. The study also highlighted the significance of varying the lattice design, indicating the pressure drop decreased when more channels were integrated.
"Our findings suggest multi-material TPMS-based cellular materials may be suitable for cold plates," assert the authors, pointing to the potential for integrating these materials within existing structures to promote higher thermal efficiency.
The lattice structures were found to possess elastic properties comparable to traditional engineering materials, confirming their viability for practical applications. By successfully isolving the relationships between mechanical and thermal performance via modifications to relative density and material properties, the study signals new directions for future research.
To conclude, with increasing electric vehicle energy densities driving the demand for superior thermal management, the innovative application of TPMS metamaterials stands as a promising path for enhanced thermal efficiency, indicating potential advancements for battery designs moving forward.