Electric Vehicle Radiator Case Study


A manufacturer of electric vehicles sought Aavid, Thermal Division of Boyd Corporation, in a thermal design challenge with cooling their radiator. Aavid was tasked to develop a practical solution while meeting a strict cost per unit in production.

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The Challenge

The manufacturer of the Electric Vehicle needed thermal expert analysis to make a reliable product in a new overall product design feature. Focusing on the unit’s radiator and existing Folded Fin structure Aavid was tasked to simulate a baseline design and optimize fin spacing and thickness to meet the requirements of 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 base plate investigations.

The Solution

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

Aavid took these finding and created a fin optimization summary. For the Aluminum and Cooper bases, testing showed by using cooper performance increased by 5C.

It was discovered that the overall airflow management system needed to be optimized in a way of minimizing flow turns and flow direction changes as well as flow 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 contour and flow field vector plots, key results, conclusions, and recommendations for improvements.

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

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