Energy efficiency is on the brink of a paradigm-shifting innovation in the shape of thermoformed plastic cooling tubes for battery cells, such as the 4680 battery used in electric cars. This patented, groundbreaking production process developed by Versa 3, makes plastic cooling tubes possible. Plastic cooling tubes significantly outperforms traditional metal cooling tubes. Not only do they present a more cost-effective cooling solution, but they set the course for the design of lighter, more nimble e-mobility vehicles.
Plastic cooling tubes are non-conductive, 50% lighter, 100% leak-proof, and 30% more cost-effective than metal cooling solutions.
Advantages of Lightweight Cooling Tubes
Traditional lithium battery cooling systems rely on metal cooling tubes, which come with many shortcomings. Most notably are the added weight of the metal and the need to coat the metal tubes with electrically-insulated material which is both labor-intensive and expensive. Plastic cooling tubes, however, weigh substantially less. In fact, they are 50% lighter. This reduction has far-reaching implications on the energy efficiency of electric vehicles. Furthermore, a lighter battery pack allows for an overall design for electric vehicles that is more agile and lightweight, enhancing their performance while conserving power.
Cost-Effectiveness
Another significant advantage of opting for plastic cooling tubes lies in its cost-effectiveness. Manufacturing plastic cooling tubes involves thermoplastic extrusion. And because plastic is not conductive, thermoformed plastic tubes eliminate the need for an additional coating required by metal tubes. The overall cost for plastic cooling tubes is approximately 30% less than their metal counterparts.
Performance and Safety with EV Technology and BTMS
How does this integrate with the broader shift in EV technology and battery thermal management systems (BTMS)? Innovative materials and manufacturing processes like these contribute significantly to the ongoing mission of improved EV operative life, performance, and safety. Alongside, they help in the reduction of greenhouse gas emissions in the transportation sector. High-capacity batteries in a limited space are a necessity for today’s EV designs, and technologies that can enhance their thermal performance at reduced costs are a necessary innovation.
Who Can Benefit?
We believe plastic cooling tubes are a promising future for manufacturers of e-mobility solutions. Whether you’re in the business of manufacturing cars, venturing into e-mobility industries, or operating within the battery industry, this revolution in cooling solutions could potentially reshape the way your products are designed and developed.
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