Hyundai Mobis Co. has developed a new battery cooling system that could solve one of the main challenges in electric vehicle fast-charging – managing excessive heat buildup. The South Korean auto parts maker aims to be the first to bring this technology to market.
The system uses a Pulsating Heat Pipe (PHP) made from aluminum alloy and refrigerant, which is placed between battery cells. The company said the material transfers heat ten times more efficiently than standard aluminum components, helping maintain safe operating temperatures during ultra-fast charging sessions.
At just 0.8 millimeters thick, the PHP technology can be integrated into existing battery designs without significant modifications. The system works by circulating refrigerant through metal tubes, creating a vibrating effect that distributes heat evenly regardless of the vehicle’s movement or orientation.
The company plans to mass-produce the technology using a simplified press manufacturing method, which could help reduce production costs. This development comes as automakers push for faster charging times while maintaining battery safety and longevity.
The innovation targets the battery module level, working with both the battery management system and cooling components to prevent cell overheating – a critical safety concern for EVs during rapid charging.
