1. Physical contact and surface treatment
The most basic way for New Energy Aluminum Alloy Radiator to thermally couple with the heat source in new energy equipment is physical contact. It is important to ensure that the heat sink is in close contact with the surface of the heat source. First, the contact surface between the two must be finely processed to make it as flat and smooth as possible. This reduces air gaps, as air is a poor conductor of heat and the presence of air gaps greatly increases thermal resistance. For example, in the electric vehicle battery cooling system, the contact surface between the battery pack and the New Energy Aluminum Alloy Radiator needs to be ground.
At the same time, in order to further improve thermal conduction efficiency, thermally conductive interface materials will be used. The most common one is thermally conductive silicone grease, which can fill the tiny gaps between contact surfaces and significantly reduce contact thermal resistance. In some new energy equipment with extremely high heat dissipation requirements, thermal conductive materials such as metal foil may also be used. These measures allow heat to be transferred more smoothly from the heating source to the New Energy Aluminum Alloy Radiator.
2. Structural design and adaptation
In terms of structural design, the structure of the New Energy Aluminum Alloy Radiator must be customized according to the shape, size and layout of the heat source. If the heat source is massive and regularly distributed, the radiator can be designed as a flat plate, and protrusions or grooves can be set at the positions corresponding to the heat sources to increase the contact area. For example, for motor controllers of new energy vehicles, the heat sink can be designed into a structure with multiple adapter bumps according to the layout of the controller chip, and the chip is directly mounted on the bumps to achieve tight thermal coupling.
For irregularly shaped heat sources, the radiator can adopt a wrapped or embedded structure. Like some specially shaped battery modules, New Energy Aluminum Alloy Radiator can partially wrap the battery and absorb heat from multiple sides. This structural design can maximize the use of the space between the radiator and the heat source, optimize the heat conduction path, and ensure that heat can be effectively conducted from the heat source to the radiator.
3. Application of heat pipe technology
The heat pipe is an effective auxiliary means to achieve thermal coupling between the New Energy Aluminum Alloy Radiator and the heat source. The working fluid inside the heat pipe evaporates and absorbs heat at one end of the heat source, and then condenses and releases heat at one end of the New Energy Aluminum Alloy Radiator. Closely connect the evaporation section of the heat pipe to the heat source, such as by welding or crimping. In high-power-density heating areas of new energy equipment, such as the central part of high-power battery packs, heat pipes can penetrate deep into them and quickly conduct a large amount of heat generated in the center out.
The condensation section is connected to the heat dissipation fins or cooling channels of the New Energy Aluminum Alloy Radiator. In this way, the heat pipe can establish an efficient heat transfer channel between the heat source and the radiator, which is especially suitable for solving the heat dissipation problem in local high heat flux density areas and improving the heat dissipation efficiency of the entire thermal coupling system.
4. Integration and optimization of thermal management systems
The thermal coupling between the New Energy Aluminum Alloy Radiator and the heat source also needs to be considered and optimized from the perspective of the thermal management system of the entire new energy equipment. In the thermal management system, parameters such as coolant flow, temperature and flow rate must be accurately controlled. For the New Energy Aluminum Alloy Radiator that uses liquid cooling, the coolant circulation system must ensure that the coolant can take away the heat absorbed by the radiator in a timely manner.
At the same time, sensors and controllers in the thermal management system can monitor the temperature of the heat source and the working status of the radiator in real time. Based on the temperature feedback, adjust the thermal coupling method between the radiator and the heat source or optimize the heat dissipation strategy. For example, when the temperature of the heat source is too high, you can increase the coolant flow or adjust the working status of the heat pipe to ensure that the heat source is always within the appropriate temperature range to achieve efficient thermal coupling and thermal management.
