Work began in one of Boyd’s dedicated design centers, where an extensive thermal analysis was performed on each of the new battery pack sizes to define the exact, optimal thermal requirements for the project. Once these parameters were defined, Boyd presented several different past cold plate examples that had been successfully implemented into electric vehicle batteries with similar requirements. Several TIMs were also presented, each featuring different thermal properties.
After evaluating options, Boyd’s engineers and the customer collaboratively decided that an aluminum liquid cold plate featuring a fiber-reinforced thermal pad would be the optimal solution. Boyd’s design center engineers immediately began developing drawings based on each individual battery pack’s needs. While initial designs were effective in handling the thermal management requirements, the cold plates were relatively large, and the additional weight on the battery became a concern.
Boyd leveraged its extensive experience with cold plate construction and began working on ways to cut down weight. After some experimentation, Boyd engineers significantly lowered cold plate weight by optimizing the size and shape of each cold plate for each individual battery. The new construction effectively cooled the extreme battery pack heat while reducing the overall weight by 40% from the initial design.
Once a design was finalized, Boyd’s prototyping team quickly began creating stamped and CAB brazed cold plate prototypes for evaluation.