The Materials Research Institute has developed a prototype for battery thermal management for electric vehicles using lattice structure materials technology in collaboration with HIVAC Co., Ltd.

The Korea Institute of Materials Science (KIMS), a government-funded research institute under the Ministry of Science and ICT, has successfully developed a prototype for battery thermal management for electric vehicles using lattice structure materials technology. This achievement was made in collaboration with HIVAC Co., Ltd. (CEO Park Jae-yong) and the Korea Automotive Technology Institute. The research team, led by Dr. Kim Sang-woo from the Smart Materials Processing Lab at KIMS, utilized a 3D metal lattice structure manufacturing technology, which controls mechanical and thermal properties through geometric design of unit cells.

Lattice structure materials form an artificial porous structure by regularly arranging unit cells of specific shapes. By designing the material, shape, size, and arrangement of the unit cells, mechanical and thermal properties can be controlled. These materials are lightweight, have excellent energy absorption, and are efficient in heat transfer, making them ideal for multifunctional applications with customized designs for various fields. They are particularly suited for use in aerospace, automotive, and marine transport vehicles due to their superior specific strength and specific stiffness compared to irregular porous structures or bulk materials. Furthermore, their ability to absorb shock loads makes them potentially useful as impact-resistant, bulletproof, and explosion-proof materials. The open lattice structure also offers a large surface area and uniform internal flow, enhancing thermal properties and minimizing pressure loss, making them suitable for heat exchangers, heat sinks, and various thermal energy management devices.

However, in some technologically advanced countries such as the U.S. and the U.K., industrialization in the private sector has been slow, except for the defense industry. The main obstacle is the increased manufacturing cost due to the complex internal shapes of lattice structures.

KIMS developed a single-layer 3D lattice structure using metal forming technology, which was then assembled in layers by HIVAC Co., Ltd., and vacuum brazing was used to join the layers and manufacture the 3D metal lattice structure material. This approach leverages traditional metal processing and joining technologies, such as plastic forming and vacuum brazing, enabling mass production without the need for additional facilities, using only existing manufacturing infrastructure.

Automobile manufacturers are focusing on the development of eco-friendly and autonomous vehicle technologies due to environmental regulations. These vehicles require high-capacity batteries, motors, and various electronic components, leading to an increase in vehicle weight and high heat generation. As a result, the focus is on developing lightweight and heat dissipation technologies.

The metal lattice structure material can be applied as a lightweight, functional component that combines high rigidity, energy absorption, and thermal management capabilities. This makes it suitable for various industrial sectors, including future transport vehicles.

Dr. Kim Sang-woo, the principal researcher at KIMS, and Park Jae-yong, CEO of HIVAC Co., Ltd., said, "Through the development and characterization of a battery thermal management prototype for electric vehicles using metal lattice structure materials, we have proven the lightweight structure and heat dissipation performance improvements of products using this technology. We expect this to lay the foundation for future applications of high-efficiency multifunctional products in various industrial fields."

The research team currently holds 8 domestic and international patents for metal lattice structure material manufacturing technologies. In collaboration with HIVAC Co., Ltd., a company specializing in vacuum brazing-based heat exchangers, the team aims to commercialize lattice structure materials for electric vehicle battery thermal management products within the next five years. If the commercialization is successful, annual sales exceeding 10 billion KRW are expected.

This research was supported by the Ministry of Trade, Industry, and Energy under the 'Core Material Source Technology Development Project (Development of Lightweight Multifunctional PCM (Periodic Cellular Material) Design and Manufacturing Technology with High Strength and Heat Dissipation Properties).'

Source: JoongAng Ilbo Online.