Tesla Motors using Dana's battery cooling tech in the Roadster

Maumee, Ohio-based Dana Holding (NYSE:DAN) disclosed for the first time today that its battery cooling technology is going into Tesla Motors' 2010 all-electric Roadster Sport, a high-performance, zero-emissions sports car.

The 2010 Roadsters, including the Sport, started production in July and are now available. The company has already delivered nearly 400 of the 2010 models to customers in the United States and European Union, Tesla spokeswoman Rachel Konrad told the Cleantech Group today.

Dana has developed its branded Long heat exchanger to extend the life of lithium-ion batteries in hybrid and electric vehicles, Dana spokesman Jeff Cole said, without disclosing how much longer the battery could last.

“The technology itself is pretty significant, and it really shows Dana’s leadership position in thermal management technologies,” he said.

The two companies wouldn't disclose the number of heat exchanger units, the terms of the contract, or financial conditions.

Dana said its heat exchange technology helps to cool a vehicle’s lithium-ion battery by transferring heat generated within the battery to the vehicle's climate control system. A temperature sensor also offers continuous feedback to the climate control system, which in turn helps to keep the battery at an ideal temperature (under 45 degrees Celsius) and extend its lifespan.

Overheating problems associated with lithium-ion batteries in laptops and mobile phones are expected to prevent major automakers from using them to power vehicles, according to French billionaire and Bolloré Group CEO Vincent Bolloré (see French billionaire launches $1.5B EV battery play and ReVolt plans for zinc-air battery to trump Li-ion with $13M in funding)

Dana supplies automobile parts such as axles and driveshafts as well as thermal management products including heat shields and evaporators, with a customer base that includes virtually every major vehicle manufacturer in the global automotive, commercial vehicle, and off-highway markets. Cole wouldn't disclose whether Dana already has contracts with other vehicle manufacturers for the Long technology. 

Cole said his company developed and is manufacturing the heat exchangers at its 170,000-square-foot advanced engineering center in Ontario, Canada.

The heat exchanger uses a patented aluminum brazing process, which helps to keep the climate control and battery coolant fluids clean, Dana said. The aluminum alloys offer material strengths and contribute to weight savings.

The chiller's compact design also offers space savings, Cole said, likening it to about the size of a shoebox. The design is intended to help accommodate the Roadster's 6,800-cell battery pack.

The 2010 Roaster Sport is the first major upgrade since Tesla began production in 2008, Konrad said, offering a number of in-cabin and under-the-hood advances. The car can accelerate from 0 to 60 mph in 3.7 seconds, compared to 3.9 seconds for the standard Roadster. The San Carlos, Calif.-based electric vehicle maker has advertised its battery pack to last seven years or 100,000 miles under normal use (see Tesla Motors on an upswing?).

The company raised $82.5 million in September, three months after the U.S. Department of Energy granted Tesla a $465 million loan guarantee to build factories (see Tesla calls new investment 'endorsement' and Who is next for $17B in DOE auto loans?).

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