Electric Vehicle Radiator Case Study


A manufacturer of electric vehicles sought Aavid, Thermal division of BoydCorporation, in a thermal design challenge with cooling their radiator. Aavidwas tasked to develop a practical solution while meeting a strict cost per unitin production.

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The Challenge

The manufacturer of the Electric Vehicle needed thermal expert analysis to makea reliable product in a new overall product design feature. Focusing on the unit’sradiator and existing Folded Fin structure Aavid was tasked to simulate abaseline design and optimize fin spacing and thickness to meet the requirementsof the customer. This included:

• Fin louver structure study.
• Fin spacing and thickness optimization.
• 5 mm taller fin optimization.
• Base plate thickness study.
• Aluminum vs. Copper fin and baseplate investigations.

The Solution

Aavid’s lab tested the louver structures to examine the impeding airflowand increase the pressure drop across the heat sink and their thermalperformance.

Aavid took these finding and created a fin optimization summary. For theAluminum and Cooper bases, testing showed by using cooper performanceincreased by 5C.

It was discovered that the overall airflow management system needed to beoptimized in a way of minimizing flow turns and flow direction changes as well asflow sudden expansion and contraction.

The Deliverables/Results

Aavid presented the customer with a full presentation report which included:descriptions of the unit and components modeled, color temperature contourand flow field vector plots, key results, conclusions, and recommendations forimprovements.

The manufacture took this report and selected the proper thermal solution vs.cost. Today Aavid provides its production needs globally.

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