Development of New Generation Battery Cooling Hoses with TPV Material

<div class="section abstract"><div class="htmlview paragraph">The market for battery-fitted electric cars continues to experience robust growth globally as well as in Indian market. During the charging process heat generation happen because of internal resistance of the battery cells and electrical connectors. Making an efficient battery cooling system is vital for all electric vehicles. One common cause of battery overheating is due to low cooling efficiency. So this research highlights the importance of scientifically designing coolant circuits and selecting appropriate coolant hose materials. Currently, EPDM (ethylene propylene diene monomer) material is widely used for battery cooling hoses due to its design Flexibility, Compatibility with a 50:50 glycol-water mixture and Resistance to thermal and ozone cracking [<span class="xref">1</span>]. This study benchmarks EPDM hose technical properties with leading EV battery cooling plastic hose materials, such as mono layer polyamide, mono layer TPVs (thermoplastic vulcanizates) and PA PP two layer hose. Comparative experiments, including fluid compatibility, burst pressure, vacuum collapse, permeability, Aging, ozone resistance and mechanical property tests, were conducted on specimens made from these different materials. The results indicated that while EPDM performs adequately, it tends to degrade under the combined influence of air and coolant liquid stresses, particularly under thermal and mechanical conditions. Conversely, plastic materials TPV (Thermoplastic Vulcanizate) significantly improve all required functional properties like low internal surface friction, low outer surface condensation, enhancing recyclability, thus supporting end-of-vehicle-life sustainability, however excluding flexibility. The advanced manufacturing process of plastic hose also demonstrate a lower Co2 footprint compared to EPDM, because of low density, weight reduction by wall thickness reduction and with higher productivity rate. This research highlights the potential benefits of transitioning from EPDM to plastic materials for battery cooling hoses in electric vehicles, resulting in improved performance, environmental benefits, and increased manufacturing efficiency.</div></div>