High-Vibration-Resistant Liquid Cooling System Protects EV Battery Packs from Shock and Thermal Runaway

The Dual Threat: Heat and Vibration

As the sole energy source for pure electric vehicles, the power battery pack directly determines overall vehicle performance. Temperature is a primary factor affecting battery performance—excessive heat or cold both accelerate battery degradation. During charging and discharging, batteries generate substantial heat. Without proper thermal management, heat accumulates inside the battery pack, causing temperatures to rise continuously and potentially triggering thermal runaway.

However, heat is not the only threat. When an EV experiences scraping, collision, or even prolonged driving on rough roads, battery cells may be squeezed, punctured, or subjected to continuous vibration. Such mechanical stress can cause internal short circuits, generating intense heat in a short time and leading to battery combustion or explosion. Traditional cooling systems focus solely on heat dissipation, leaving batteries vulnerable to vibration-induced damage.

To address this dual challenge, the Tenglong Automotive engineering team has developed a high-vibration-resistant liquid cooling system that combines efficient heat dissipation with mechanical shock protection for lithium-ion battery packs.

Engineering Excellence: Integrated Cooling and Shock Absorption

The RD14 project introduces a robust thermal management architecture featuring multiple protective layers:

⦁ Motorized Drive Mechanism: A horizontal rotating first shaft is installed inside the bottom of the housing. One end of the first shaft passes through the housing and connects to an electric motor, which is mounted inside a motor bracket attached to the lower exterior of the housing.

⦁ Dual Buffer System: The housing and protective cover are connected through two mutually symmetrical buffer mechanisms. These buffers effectively absorb vibration energy, preventing road-induced jolts from damaging the battery pack during vehicle operation.

⦁ Elastic Support Cooling Plate: The cold plate is designed with elastic support to absorb assembly tolerances and maintain excellent thermal contact throughout the battery pack's service life.

⦁ Fin-Integrated Liquid Cooling Structure: Based on the battery pack configuration, the system incorporates a hybrid fin and liquid cold plate design, optimizing both heat transfer surface area and coolant flow distribution.

Key Innovations for Harsh Environments

1. Shock Absorption for Rough Roads: The buffer mechanism effectively cushions the battery pack against road-induced vibrations and jolts, preventing mechanical damage that could lead to internal short circuits or thermal events.

2. High Thermal Conductivity: The system delivers excellent thermal conductivity and high heat transfer coefficients at the battery wall interface, enabling rapid heat dissipation, high cooling speed, and superior cooling efficiency.

3. Compact Structural Design: The system features a reasonable, easy-to-assemble structure with good heat dissipation performance. Its compact layout facilitates space-efficient integration into modern EV architectures.

Proven Results and Intellectual Property

The project represents an improvement on the company's existing invention patent: "A Heat Dissipation System for New Energy Vehicles" (Patent No. ZL201810502302.7). The patented design includes a housing with multiple air inlets and outlets equipped with opening control valves, two horizontally fixed partition plates inside the housing, and a battery pack mounted between the partition plates. The system features rational construction, easy assembly, excellent heat dissipation, and strong vibration resistance.

The final evaluation committee confirmed that the system has been successfully applied to the company's vehicle product line, where it improves battery cooling efficiency, provides effective vibration buffering, and delivers positive economic returns through commercial sales.

Commitment to Comprehensive Battery Protection

The RD14 project reinforces Xiangyang Tenglong Automotive's commitment to holistic battery safety—addressing not just thermal management but also the mechanical stresses that vehicles encounter in real-world operation. By integrating this high-vibration-resistant liquid cooling system into our vehicle lineup, we ensure that every battery pack remains safe, efficient, and durable even under rough road conditions and unexpected impacts.

RD14 Project Proposal for Design of a High-Vibration-Resistant Liquid Cooling System for Lithium-Ion Battery Packs in Electric Vehicles