Application of hose clamps in thermal management systems of new energy vehicles: special requirements for battery cooling to hydrogen energy pipelines

Keywords: new energy vehicle clamps, battery cooling, hydrogen energy pipelines, lightweight

abstract

New energy vehicles have higher requirements for the temperature resistance, medium resistance, and lightweight of clamps. This article takes Tesla Model 3 and Toyota Mirai as examples to analyze their clamp technology solutions.

4.1 Battery cooling system clamp

Corrosion resistance to ethylene glycol: using 316L stainless steel substrate+PVD coating, after soaking in 50% ethylene glycol solution for 1000 hours, the corrosion rate is less than 0.01mm/a.

Low permeability design: By optimizing the curvature of the clamp teeth (R=1.5mm), reducing the variation in hose wall thickness (± 0.05mm), and lowering the coolant permeability (<0.1g/m 2 · day).

4.2 Hydrogen fuel cell pipeline clamps

Anti hydrogen embrittlement treatment: Select austenitic stainless steel (such as 310S) and add 2% nitrogen element, with a hardness HV ≤ 200, to avoid brittle fracture caused by hydrogen atom penetration.

High sealing pressure: Adopting a double-layer clamp structure (inner stainless steel+outer composite material), the leakage rate is less than 1 × 10 ⁻12 Pa · m 3/s under a hydrogen pressure of 70MPa.

4.3 Lightweight and Integrated Design

Plastic metal composite clamp: The matrix is made of PA66+30% fiberglass reinforced material, and the surface is coated with aluminum alloy toothed belt. The weight is reduced by 40% compared to all metal clamps (such as from 80g to 48g).

Sensor integration: Strain gauges and temperature sensors are embedded in the clamps to monitor real-time pipeline pressure (0-10MPa) and temperature (-40 ℃ to 150 ℃), and data is transmitted to BMS through CAN bus.

4.4 Industry Certification and Standards

UL 2586 certification: Passed the hydrogen cycle aging test (1000 charge discharge cycles), and the clamp has no cracks or leaks.

GB/T 34425 standard: Simulate vehicle vibration (frequency 10-200Hz, acceleration 5g), clamp torque attenuation rate<8%.

conclusion

New energy vehicle clamps need to balance safety and lightweight. Through material innovation and structural optimization, they can meet the extreme working conditions of battery cooling and hydrogen energy pipelines.