The high-frequency insertion and removal heat dissipation problem of new energy battery swapping equipment: A stable solution using thermal conductive silicone sheets

In the current era of rapid development of the new energy vehicle industry, the battery swapping mode, with its advantage of "minute-level charging", has become one of the core paths to solve the problem of range anxiety. The stable operation of the battery swapping equipment directly determines the charging efficiency and user experience. Among them, the heat dissipation performance is the key technical bottleneck of the battery swapping equipment - the battery modules and power devices inside the equipment will quickly accumulate a large amount of heat during high-frequency insertion and high-power charging and discharging. If the heat cannot be promptly discharged, it will not only lead to a decrease in the equipment's operating efficiency, but also cause safety hazards such as uncontrolled battery heat dissipation and aging of electrical components. Among various heat dissipation materials, conductive silicone sheets, with their unique performance advantages suitable for the battery swapping scenario, have become the ideal choice for solving the heat dissipation problem of battery swapping equipment.

The working environment of battery swapping equipment imposes extremely strict requirements on heat dissipation materials: they must not only have effective heat-conducting capabilities, but also be able to withstand the mechanical vibrations caused by frequent plugging and unplugging, as well as the environmental tests of high and low temperature cycles. At the same time, they must also meet the insulation safety standards under high-voltage electrical conditions. The core characteristics of thermal conductive silicone sheets precisely match these requirements.

From the perspective of thermal conductivity: The thermal conductivity coefficient of the thermal silicone sheet ranges from 1.0 to 13.0 W/m·K. It can be flexibly selected according to the heat dissipation requirements of different components of the battery equipment. Whether it is filling the gap between the battery module and the heat sink base, or the heat conduction between the power module and the aluminum substrate, the thermal silicone sheet can closely adhere to the contact surface, eliminate the thermal resistance caused by the air gap, achieve rapid heat conduction and diffusion, effectively reduce the operating temperature of the components, and avoid the generation of local hotspots.

In terms of scene adaptability: The flexible and compressible nature of the thermal conductive silicone sheet enables it to effectively handle the frequent plugging and unplugging situations of battery swapping equipment. During the long-term use of the equipment, vibrations and deformations are inevitable. However, the thermal conductive silicone sheet can maintain a close fit with the heat dissipation surface through its own elastic changes, without any issues such as detachment or cracking, ensuring the long-term stability of the heat dissipation effect.

In terms of insulation safety: it is another core highlight of the thermal conductive silicone sheet. The internal components of the battery replacement equipment involve high-voltage circuits, and the heat dissipation materials must have excellent electrical insulation properties. The insulation strength of the thermal conductive silicone sheet is very reliable and complies with the UL94 V-0 flame retardant grade. It can not only prevent electrical conduction risks along the heat transfer path but also effectively stop the spread of fire when exposed to open flames, providing a dual guarantee for the safe operation of the battery replacement equipment.
 

In addition, the ease of installation of the thermal conductive silicone sheet also brings significant advantages to the production and assembly of battery swapping equipment. Compared with traditional thermal pastes and thermal gels, the thermal conductive silicone sheet does not require additional curing time and can be directly cut and adhered, simplifying the assembly process, significantly improving production efficiency, and also reducing the difficulty and cost of later maintenance.

Selecting the appropriate thermal conductive silicone sheet can not only enhance the operational stability and service life of the battery swapping equipment, but also provide a solid material support for the high-quality development of the battery swapping mode in new energy vehicles.