Hyundai Ioniq 5: Integrated cooling plate | Battery Pack Breakdown

[@HalomasterObi1177]

I'm loving all of the Ioniq 5 content lately. It's very rare to see your current daily driver vehicle torn down and get some expert opinions on how it was made. So far everything I've seen gives me confidence that I made the right choice for my first EV.

[@fjalics]

I am secretly hoping that these EVs last longer than gas cars. Some Tesla M3s are hitting 300k miles. These are too new. My brother had a Rabbit GTI back in the day. The Ionic 5 reminds me of that, only much newer, and has all the stuff I love about EVs.

[@MilodeVries]

​@@fjalicsthere are leafs that are well over 10 years, with just tires and windshield wipers replaced. Once this sinks in, EV adoption will skyrocket

[@tdome3000]

The Ioniq 5 has very poor battery cooling/heating. The difference between the lowest and highest temperature can be 10° C, which means that the car often rapid- and coldgates, sometimes in the same charging session.

[@davidbeppler3032]

@@fjalics TM3 made after 2019 should last 750k miles.

[@fjalics]

@@davidbeppler3032 I got mine Nov 2018. Only got 60k on her. Dual motor too. I had a Prius before that. Off the line is quick. 🙃

[@lemongavine]

When they flipped it, I didn't realize the cells were removed. I was like, GREAT SCOTT, they are going to flip it manually with only two people? Phew

[@ericplatzke]

💪

[@Stefan_Dahn]

When you hear the bells ringing, it is (usually) time for the unique Munro spinach break, mandatory for each employee. Sandy decided, that this saves costs vs. using a crane or a six million dollar man or a bionic woman. 😉

[@lemongavine]

@@Stefan_Dahn 😜😜😜

[@Anshandbhavikarefflover]

​@@Stefan_Dahn😂😂😂😂😂😂😂😂😅

[@j4k3br4k3]

Edge cooling pouch cells was cutting edge in 2015, glad to see it finally made it to production. You get the most efficient heat transfer by going in plane to the electrodes vs. through the stack to another fin and down to the cold plate.

[@Stefan_Dahn]

Bjørn Nyland discovered highest delta temperatures between min and max temp. in the pack. Over 10°C (a.k.a. Kelvin). That is very bad.

[@USNEM]

So many amazing engineers in these comments. Thank you

[@instanoodles]

You should email your comment to Hyundai, im sure they will give you a job right away!!

[@xxwookey]

@@Stefan_Dahn That does seem a significant variation. What are other battery designs getting? This battery does charge very fast so one would expect a correspondingly higher cooling load and thus a higher temp differential for a given cooling capability. A higher differential is not necessarily bad so log as all cells are kept within reasonable wear levels. The devil is in the details here. perfectly consistent temps would be nice but you never get that in real-world cooling systems, so the question is 'is it good _enough_?'. Where I guess 'good enough' means >80% capacity after a decade. The car comes with an 8-year 100,000 mile battery warranty, so they are expecting at least 500 charges to produce less than 30% degredation.

[@sprockkets]

@@Stefan_Dahn Dude Celsius isn't Kelvin LOL

[@JeffEdmondson]

I was just linked to this video. Wow, you guys know your stuff. My brain is throbbing from all of the info. Keep it up!

[@MunroLive]

More to come!

[@andrewt9204]

I feel like the benefit of an easier to disassemble pack is recycling. I know you can shred the whole thing, but I think it would be more environmentally friendly to separate as many of the big components first as possible. Yeah it's a one time scenario, but it's also a major event. Maybe if you can get the design so lean as to not matter as much. The 4680 pack feels like it's getting there. I'm not as concerned about pack repair as I once was, I think battery chemistry and design will get to a point where failure will be so low as to not matter. Failure rates are already pretty low with current tech. Seems like most repairs were on older vehicles with suboptimal thermal management.

[@Teddy_M85]

Battery pack price will continue to decrease as well. But until it goes down to sub $5k per pack, there will be a lot of ppl that will hold off on buying an EV. I plan on trading my MY after the warranty expires. I think we are still 8-10 years away from cheap battery pack replacement.

[@andrewt9204]

@@Teddy_M85 Yeah, also a reason I'm less concerned with pack repair. Not only do you have to gimp the new cells to match existing degradation, it's generally not an easy process. And yes pack prices will come down with scale. ~10y is probably a good estimate. I will continue to monitor my M3 pack health. As long as it shows no sign of accelerated degradation, I plan to keep it for at least a few years after the warranty. 10 years at least unless something really revolutionary comes out. Already owned it for 2.5 years with maybe 3-4% degradation. That 9/10 year mark is where I break even with gas savings vs. extra vehicle cost of what I had.

[@Zeesneakyninja]

When the pack is worn to the point that it will be recycled, you are probably recycling the entire vehicle anyway.

[@Stefan_Dahn]

@@Zeesneakyninja What about single cell failures?

[@USNEM]

Can you point to me where this mystical "Shredder" is? Or did you hear this from Munro?

[@1209astine]

As an EV6 owner(Love the car), I've been waiting to see my battery pack internals. Appreciate the walk-thru!

[@kyleraine2395]

Great info to see. Would love to see a teardown next of the ICCU especially with the NHTSA investigation and recent software inspection they just released.

[@FuncleChuck]

The fact that a software fix came out makes me think this was a software problem to start. Old school firmware guys are pretty notorious for being ridiculously slow and lazy to do anything, and a 6-12 month release cycle to fix ridiculously bad errors is par for the course.

[@Stefan_Dahn]

static.nhtsa.gov/odi/inv/2023/INOA-PE23011-2700.PDF

[@Stefan_Dahn]

static.nhtsa gov/odi/inv/2023/INOA-PE23011-2700.PDF

[@ritchie70]

@@FuncleChuck My (vague) understanding is that the software fix is to prevent too much flow thru the ICCU under some circumstance(s) causing the fuse to blow. Once it blows the unit needs to be replaced, but the software lowers the max power (?) that will be sent under that condition and keeps it from bricking.

[@LichaelMewis]

​@@ritchie70and prevents the car to charge (AC as DC is unaffected with this) at rates it was marketed to do which sucks.

[@lehelzelenka207]

"getting a single module out, usually is not a super simple task" and goes on to question the need for a practical and easy to remove and reapply rubber seal, just for the technician to say this pack is one of the easiest to disassemble! 😂 Dude was driving his point for a whole minute and the tech guy flipped the conclusion 180° 😂

[@kjer6071]

That internal welding looks to me to be more likely spoolgun rather than tig. Though I've done lots of welding, I'm by no means an industrial expert (I know only what I know and not far out of my experience). I'd be interested in what you think.

[@RayNLA]

Great video with easy to understand descriptions, without tons of acronyms to decode. Thank you gentlemen!

[@MunroLive]

Glad you enjoyed it!

[@jway288]

Great video. Loved that the old man, tesla fanboy, wasn't there. Any video he's in is purely propaganda for musk/tesla. Really enjoyed good neutral comparisons between all the ev platforms. Thanks again for the great video.

[@KiwiMechEng]

Yes, the staff have proven to be highly professional and unbiased. Exactly what I expect from university training.

[@waynerussell6401]

What we want in a teardown is critical analysis. Staff do not have the authority to criticize potential customers. Owners do. Hence why the failure of the old design Hyundai pack is not mentioned. It has high temperature delta between cells which results in charge throttling and potential cell failure, as demonstrated by Nyland. Tesla does not.

[@richardb9591]

Great informative video, thanks. That SMC (unsaturated polyester) bottom "shield" for the high voltage battery pack sure looks vulnerable to impact damage from debris on the road. Shouldn't Hyundai/Kia/Genesis use more substantial material for the shield to help prevent impact damage to the battery pack assembly including the battery cooling system (i.e. cold plate)?

[@Hall102]

There's two recent cases in Canada where (what appears to be) minor damage to the shield voided the battery warranty. The cars needed a $50k replacement battery!

[@migueralliart]

I am soooo glad I got the extended warranty bumper to bumper on my ioniq 5. Can't imagine myself working on anything in here.

[@budgetaudiophilelife-long5461]

🙋‍♂️THANKS ,JULIAN,ANTONIO AND THE MUNRO TEAM 🤗😎💚💚💚

[@joebass5163]

Two separate instances of battery pack impact damage and insurance companies scrapping the vehicles after learning replacement cost is 60k Canadian. Neither vehicle had any warning lights or indication of faults in the computers. Not acceptable.

[@nc3826]

What's unacceptable about getting a new EV? If an insurance company stupid enough to pay for it. When did scrap yards go out of business? There's always a lower cost alternative. Hyundai deals with realistic problems Instead of blaming others such as calling it driver error. Thanks for the BS scaremongering FUD. FWIW Rusting Cybertrucks. Is truly Unacceptable...

[@johnpoldo8817]

Wow, more than I ever wanted to know. Julian & Antonio are very knowledgeable.

[@bhmbill]

Would the thermal interface material have an added benefit of reducing shock by providing some cushioning the the battery packs? As well as reducing noise.

[@MrVegasoul]

TIM can provide the stability at vibrational stability with modular design feature. The battery cell temperature shows the lowest level because the cell resistance is very low compared with others. Integrates cooling improves the pack assembly and disassembly which is good for productivity and recycle.

[@randomdriver]

I would hope the smc? cover would be a little bit harder. Over here if there are any dents in the battery back if will fail yearly inspection and the battery back must be replaced. I just wish the battery packs would be better protected from outside forces.

[@qa1e2r4]

it have the cooling plate then the thermal paste THEN is the actual battery cells. But yeah if you decide to off-road/skid off on some large rocks. You will need some battery work. And looking how it is assembled you will need a whole new battery. Once the cooling plate is damaged no one will be reapplying the cooling paste just to save you a few thousand bucks when they can overcharge you for everything :D

[@xxwookey]

@@qa1e2r4 There is a post in these comments about someone getting a new paste+cooling panel+cover fitted (due to damage to the bottom of the pack). So it is happening.

[@mikeselectricstuff]

the launch models of the I5 had a solar roof for charging - would be interested to see how this was implemented without having to close the contactors - I'd imagine a seperate low-current feed into the pack with diodes for isolation - did you see any signs of this ? Would also be interested to see details of how they do 400V charging, and what power they can do this - ISTR reading they use the motor as part of the converter, like the Renault Zoe did for high power AC charging. Also the AC inverter for V2x - is this part of the onboard charger ? Hopefully you'll be diving into these boxes soon...!

[@BatterVswithAntonio]

I'm sure any external power was routed through the OBC or inverter just to prevent over-charge. I'll make sure to bring this up in the discussions to make sure its addressed in the videos. Thanks for the input Mike.

[@mikeselectricstuff]

@@BatterVswithAntonio But if solar was routed through the OBC or inverter, it would have to close the pack contactor, and the contactor coil current to do that would eat into any gain from the solar panels. As solar would be pretty low power, and nowhere near the 800V pack voltage, I'd think the best way to do it would be to feed it into the pack housing, where a boost circuit would convert it up to 800v, protected from overcharge by a simple overvoltage cutout and diodes to prevent backfeeding.

[@coreyverisario6570]

Probably just charges 12v batt. To run stereo, HVAC fan maybe. Things like that.

[@peteglass3496]

Good question.

[@phillyphil1513]

@@coreyverisario6570 re: "Probably just charges 12v batt. To run stereo, HVAC fan maybe. Things like that." yeah, it was just a fancy maintainer (ref: Battery Tender) for the 12V, which indeed benefits the HV battery albeit indirectly by way of the DC to DC converter not having to turn on. people still don't seem to process how there's just not enough surface area and not enough output to bother with the complexity of integrating it to the HV system to begin with, and even then the output that it DOES produce is dependent on weather, time of day, etc. yeah, all the same variables that impact Renewables on a large scale also impact small scale Renewables placed on the tiny roof of a vehicle. this reality combined with the COST (God forbid we forget about that) is why the Solar Roof was only offered on the limited run Launch edition, very similar to the other Hyundai products that got Solar Roofs. it's purely a "sales gimmick" and not meant to be anything more, and that's fine as all the Manufactures offer a "gimmick" in one form or another to make a "green statement" and entice consumers to buy their vehicles over the competition, naturally some features are more "gimmicky" than others.

[@dominikhejl5748]

since i work on maintenance of hyundai EV's this is nice analysis of what may i expect in the future to work on.

[@Chris28mmz]

The future is now!

[@bobadingo]

Molded composite battery chassis would be the way to go that slides into place and locks in with quick release,& power plug, cooling lines.. .

[@richardnedbalek1968]

21:42 Julian’s Shinola watch is based in Detroit, just like Munro and Associates. Class! 😉

[@stephanematis]

I love these presentations as the focus on a brief overview requires a clear understanding of the totality of the related technology. Seeing how I understand what I am being told, this truly leads me to realize how well Munro Live folks are subject matter experts. Well done.

[@tesla_tap]

Thanks for the great view! I like the liquid seperation from the pack, but it would seem the cooling/heating would be very uneven between the module nearest the inlet and the module at the outlet. It also seems like a lot of heat/cooling would be lost from the bottom to the outside as that thin plastic sheet doesn't seem like much insulation. Perhaps it is made up with a beefier coolant/heat system, but that adds cost and reduces efficiency.

[@patreekotime4578]

With the exception of extreme cold weather environments, mostly you *want* heat to dissapate from the pack. If anything this probably helps reduce the demands on their cooling system.

[@ApparitionElectronic]

Actually the design of that serpentine pattern has the hot side run parallel to the cool side which results in a pretty even temperature throughout the pack. Certain arctic birds have a circulatory system that works a lot like this to prevent them from suffering shock from ice cold blood reaching the heart...

[@tesla_tap]

@@ApparitionElectronic Makes sense. Thanks!

[@USNEM]

We have another exceptional engineer in the comments. Thank you

[@nilsfrederking62]

Thought the same, it will be very interesting to see winter performance of the Ioniq 5. If you try to warm up the battery from underneath, nearly half of the heat will dissipate to the outside.

[@evan010101]

We had a car that was written off (totalled) due to a small scrape to the cooling plate, causing the coolant to escape. Repaired it with JB Weld and retitled it.

[@celeron55]

Those circuit boards in the modules are simple breakout boards and the components on them are fuses (it's even labeled on the board). All the things lucid had on the module circuit board are external to this module.

[@kens97sto171]

Great video, I wonder if the thick layer of Thermal silicone also helps with shock absorption? to the battery cells, and or to help with expansion when the cells get hot?

[@kingdeography]

This is very great content and very through engineering review. I own an Ioniq 5 and myself am also a battery module designer (pouch cell). I can see that the thermal management design between module and pack can improve for sure. 3mm of TIM is asking for weight/thermal resistance trouble. Are there vent ports in the pack? Thermal propagation is becoming a heated topic in the industry and love to see how pack design will transition to eliminate TP.

[@nilsfrederking62]

A good thermal management is crucial for longevity, I have a little bit my doubts about this design.

[@boostav]

They went over it, there are no valves just that gasket designed to release pressure in the event of overpressure.

[@KevinT3141]

TeslaBjorn's drives in this car while using Car Scanner showed a huge difference between the highest and lowest temperatures in the pack (I think it was 8 or 10 °C), so yeah, this cooling plate with that much TIM is non-optimal and results in charge speed throttling on long high speed road trips. I appreciate how much more serviceable, and probably recyclable, this pack is compared to some of the others though.

[@phillyphil1513]

re: "Thermal propagation is becoming a heated topic in the industry..."

[@rossr6616]

​@@phillyphil1513It was a very heated exchange

[@57wadey]

Amen.... Finally coverage of the battery removal process. Well done Munro Live!

[@energyeve2152]

Great getting to see a pack breakdown. I’m definitely going to be consuming more content like this. Thanks for sharing

[@MrOmin13]

Given the separation of the packs and the coolant, what are your thoughts on the reasoning behind the expensive battery coolant they use and the maintenance on said coolant.

[@ME-cb1vw]

is the coolant for ioniq5 also expensive? I just remember expensive coolant for Kona

[@franklyfrank123]

Such a great car! Great engineering!

[@Doctorbasss]

21:30. These fusable link I guess are to protect LV modules short circuit, however these are in serie anyway so all the HV could come across these fuse somehow. So why these are not glass or sand or ceramic surrounded to not have a plasma event? Normally fusable link are on each cells in parallel so this protect for 3.7V maximum, however these big fusable link are at the HV level !

[@mudpuddle8805]

The Ionic battery pack is $60k from Hyundai. The brand new car is only $50k.

[@dmitripogosian5084]

To be exact, it is like $56,600 Canadian dollars quoted in Canada

[@mudpuddle8805]

@real100talk5 Holy cow, that's terrible... Or great depending if you are buying new or buying used! I think I'll pass.

[@nc3826]

FYI the post shows how easily repairable it is.... Google what a scrap yard is.... Plus the need for a brand new battery pack is infinitesimal..

[@nc3826]

it's better than owning a Tesla... since if you get a scratch on a Tesla you can't even use their superchargers...

[@mudpuddle8805]

@@nc3826 Seriously? Until recently, I was under the impression that if you buy a Tesla new, you get lifetime free supercharging. I just learned that hasn't been the case for years. Then I found charging at a public charger can cost more than a tank of gas! This electric car thing is going downhill fast.

[@dontcare563]

Is this the battery pack that costs 60K from the dealer to replace that's been in the news from 2 different customers/stories lately?

[@gfoote1]

Finally, more detail on the Ioniq teardown. Great analysis. Can't wait for more videos!

[@chrisvanzadel6944]

12:02 There is a trend 'repairability' to become mandatory by law(consumer rights/environmental motives) It already has a legal basis in some countries and the EU is working on it. Maybe that is the reason for it?

[@bartwaggoner2000]

Do you repair your cell phone battery? I think EV cars, especially the cheaper ones, will move in the disposable direction (sadly)

[@flaviandd]

@@bartwaggoner2000 Yes, I do. I usually replace them after about 2 years or so, when they start having less and less capacity. And they usually cost less than 50 USD to replace. A car battery costs between 5000 USD and 15.000 USD. So you bet I would like to be able to repair it in case of damage, accident or expired warranty. Especially once the used and second hand market of such modules will start to grow. It will be easy to swap, re-purpose, repair or upgrade such batteries. It's 10 times better than the 4680 sealed crap, for example. The right to repair does matter!

[@bartwaggoner2000]

@@flaviandd there is no 'right to repair' - what is that, some God-given natural right? There is a right to just not buy it if you don't want to - the free market.

[@rkan2]

You cannot easily swap modules from most packs - I imagine this pack to not be much different. And I don't mean physically but when it comes to the delta between cells..

[@chrisvanzadel6944]

@bartwaggoner2000 The right to produce disposable products even though they are superior on any level is not God-given either. And should not be attributed to evolution either. Let alone the free market...

[@davenone7312]

It really shows how Hyundai did not go Cheap like Toyota Ford and others did on the battery pack. Hyundai really puts out a far higher quality product. You pay just a few extra dollars perhaps but Wow they really did step up to the plate here unlike the other car makers. They just beat the heck out of Toyota here!!

[@CCRoselle]

We have a Prius V and are very happy with it . We have been looking at the Electrified G80 to replace our other ice car, after seeing the stories about MINOR pan damage totaling the car...NO WAY, NO HOW!!! The newest Prius is looking better every day. I was looking for a bit more room and comfort, but I can do without the super-premium insurance costs.

[@larryjenkinson5525]

🇦🇺 Would like to see an animated exploded view of the battery pack. This video seems to already have the components disassembled.

[@celeron55]

To me it seems the bossed areas below the modules essentially turn the coolant flow of each module parallel to each other, instead of being in series. That's really smart. They controllably "short circuit" the main coolant channels, some for each module.

[@ultrastoat3298]

1:55. That’s a long path. Won’t there be a huge coolant temperature delta between the cells nearby the inlet vs the outlet?

[@xxwookey]

Apparently these packs can have a delta up to 10C, so yes this may be an issue. Do other packs have parallel, rather than serial cooling paths? There could still be differential cooling in that case due to 'shortest path' issues.

[@DaDdy79462]

It rained a lot recently causing some flooding under train bridges, how protected is the battery if I had to drive through them?

[@danchesney631]

The rivnuts would mitigate a galvanic corrosion issue that might exist with threading steel bolts directly into an aluminum extrusion.

[@maxtorque2277]

Interesting to see the integrated fuses for the cell voltage measurements on each of the module interface pcbs! Very nice (if somewhat costly) addition to avoid shorts in the BMS wiring leading to a serious thermal event

[@marsrover001]

At least it's possible to replace a bad module. Unlike other manufacturers filling every void with epoxy.

[@PeaceChanel]

Thank You for All that you are doing for our Planet Earth.... Peace.. Shalom.. Salam.. Namaste 🙏🏻 😊 🌈 ✌ ☮ ❤

[@tomoblonsky3173]

Regarding the embossed areas on the cooling plate, don't those raised areas actually bring the cooling plate surface closer to the bottom edge of the pouch cells, thus reducing the volume of TIM required? It looks like the embossed areas provide clearance for the module structure holding the pouches together...

[@patreekotime4578]

Yup, that was my thought exactly. The depression in the center gives clearance for the central structural bar and the depressions on the ends make room for the plastic housings for the modules. Antonio *did* mention that it gives clearance for that steel bar.

[@KiwiMechEng]

I expect it's simply to improve the stiffness of the raised area to minimise the chance of delamination with the thermal pad.

[@hoffinger]

Because there is a raised area there is a also a depression. The depression needs to make contact too.

[@No-thing-ness]

Great review old mate. I’m new to your vids but I would very much like to see a strip down. I understand this is recorded live though. Cheers

[@tazeat]

I'm not the expert, but arent most of those aluminum welds MIG, not TIG? They look like MIG welds to me on the pack assembly? Can you point out where they were doing manual TIG welding?

[@BatterVswithAntonio]

Most are friction stir or MIG, the round bits were manual.

[@peeweedan9]

I'm not an expert either, but I'm quite certain most, if not all, the welding in that extruded aluminum structure is robotic MIG welding. The start locations for similar weldments are very consistent, and in places they wouldn't typically be. Starting off the joint ensuring arc is properly established perhaps. This can be seen along the length of the structure around each of the perimeter tubes, internally where part of the weld bead creeps up the "rib" extrusions on either side, and at the box tubes at the coolant inlet side. But like all processes, there are sure to be QA verifications and manual touch-up of areas that need it. So not every weld may look, or be applied, the same.

[@nilsfrederking62]

@@peeweedan9 The welds except the friction welds look horrible, my guess is that they are manual welds. one weld even does not connect the parts properly over half of its length. No idea who let that casing pass quality control.

[@michaelchu1602]

I just came from the video about the $60,000 cost to replace the battery on the Ioniq 5. That's just dirty. After hearing about the modular battery design, it sounds like we can just replace the affected modules without the need to replace the entire battery back. Not sure if anyone will want to get the Ioniq 5 or any Hyundai EV anymore after that...

[@FutureSystem738]

If I owned one, I’d sell it…. And buy a Tesla. Less chance of damage, and absolutely worst case, about 1/3 the price for a new battery.

[@clansome]

@@FutureSystem738 Wouldn't have a Tesla even if it was free.

[@FutureSystem738]

@@clansome LOL :-) More fool you. We’ve had one for well over four years, and it’s the best car I’ve had, by far, ever.

[@dave24-73]

I think I saw the same story, the bigger question is there isn’t anywhere near 60k in materials there so this is clearly a con.

[@dave24-73]

@@FutureSystem738until the underside is scratched and the dealership give you a $60k bill. Which is essentially what happened in the story he referenced.

[@motorv8N]

Love these videos but would have liked to see them build out a section or two to see how all the parts assemble. Also it’s a shame that even though the pack is meant to be serviced you can’t apparently do anything in the event of damage but replace it all. Doesn’t make the effort of modular design worthwhile.

[@ferkeap]

Is the coolingplate protection-cover also an isolation piece it doesn't seem so. That would improve the cooling/heating effective and Effeciency

[@xxwookey]

Yes, this seems like an omission. Just 10mm of foam in there would make battery warming dramatially more efficient. maybe there is enough self-heating in use for it not to really matter? But for things like camping mode overnight we'd really appreciate some insulation.

[@deltajohnny]

Thanks to both! 👏👏

[@MunroLive]

Thanks for watching!

[@supernumex]

25:46 Are there resistors on the other side of the pcb? It looks to be just some fuses and connections for the individual cells. Balancing is probably done elsewhere?

[@BatterVswithAntonio]

All fuses. Balancing done in the spine based boards.

[@willie6184]

You probably know by now you dissected a $56649.98 battery pack, nice

[@dmitripogosian5084]

That's in Canadian dollars, so they do not care :)

[@reefgratos2035]

Replacing the hv battery on the ioniq5 cost around $ 40k usd. It doesn't take much to damage the skid plate, any damage to the skid plate will hit the battery causing a small dent,. hyundai dealership are private owners and will quote you all kind of prices but all of them will quote you the same price for the part number. And the part number will be around 40k usd. In other words, do not hit anything on the road with the ioniq5, because damage done to the hv battery will not be covered by the warranty. Just like windshield, or tires.

[@wizzyno1566]

The cooling pack looks very neat.

[@MunroLive]

Would you say it looks... cool? 🤣

[@4literv6]

@@MunroLive it's certainly a design that flows fluid fluently. 😀

[@Bowhunters6go8xz6x]

I've seen the batteries are super expensive, replacement Ioniq5 batteries from Hyundai cost around $60,000 just for the pack, not including labor. One guy he paid $55,000 for the car and hit something on the highway that damaged the safety cover and Hyundai wanted $61,000 to replace the battery pack, his insurance company totalled the car even though the body was untouched by the item he ran over.

[@JohnLee-db9zt]

This guy is all CAP. It’s $30,000 USD. I looked it up. It was not Hyundai corporate that charged $60,000 CAD. It was the greedy Hyundai dealer and incompetent insurance adjuster.

[@JohnLee-db9zt]

Also the damage was caused by the driver so the battery was not covered by warranty. It wasn’t only the battery cover that was damaged but also the battery cooling system, so it couldn’t be repaired by the dealer.

[@Bowhunters6go8xz6x]

@@JohnLee-db9zt - According to the report he hit something at night in the dark laying in the road that probably fell from another vehicle.. NOT his fault.

[@xjdisuehd]

Question - why not install pressure relief valves on two diagonally opposite ends and have air channels across all modules so pressure in the entire battery pack is same. Or in case of extreme thermal runaway, there can also be rupture discs?

[@xxwookey]

Because it would (probably) cost more than using the expanding seal they've used (which obviates the need for such vents?)

[@MAESTROLIDER]

Thank you for the video 😊 Will you cut the battery case to show the cross section?😊

[@StayFoolish2Learn]

Very valuable insights. Thanks for that. @24:53 Do we know whats the cell chemistry ? Whats percentage split of NMC ?

[@ouch1011]

Is there anything that thermally isolates the cold/hot plate from the battery box? Or does the battery thermal management also have to heat/cool the entire battery box whenever it wants to heat/cool the cells? I’ve noticed that my Ioniq5 battery loses a lot of heat very quickly in cold temperatures. Losing heat from the battery is great when it’s hot outside, but not great when it’s very cold and you want to DC fast charge at a decent rate. I highly appreciate Hyundai/Kia’s emphasis on serviceability. I know that Munro believes serviceability is a waste of time/money, but for those of us who actually own older cars and/or those of us who work on them, ease of serviceability is a substantial consideration. Even if Hyundai/Kia only replaces entire packs under warranty, having the ability to replace a single failed module in the pack for $2000 is going to be much more achievable than being forced to replace the entire pack for $15000+ (a la Tesla) when it’s customer pay. It also makes the pack way easier to recycle or repurpose when it is no longer fit for use in a car. Seeing how the Ioniq5 is built, it gives me a lot more confidence to keep it outside of the warranty period than my Model 3.

[@nilsfrederking62]

Model 3 and Y have proven to have very high longevity and very good winter range, as the whole thermal system is very mature an efficient (oktovalve and heat pump). The Ioniq 5 has to prove its longevity, I have my doubts with the only one sided cooling and very little cooling surface; thermal management is crucial for battery life. In winter conditions it will be very difficult to heat the battery up, as there is only minor insulation of the cooling plate to the outside (glasfiber is not a very good insulator) .

[@mrrkrr]

10:07 LOL why y'all got one of those hospital sliding table things? 😂

[@bartwaggoner2000]

Perfect for the 500Kg patient!

[@BatterVswithAntonio]

Good standing desk!

[@Wrkncacnter777]

Tens of thousands of those are sitting in medical scrap facilities waiting to be broken down for scrap metal and the landfill. They probably rescued some of them and gave them a second life.

[@wendellsatterwhite50]

I like serviceability of this module. I know your primary focus is on reducing assembly costs, but at some point things break and have to be repaired. If you watched some things that have to be preformed in order to do repairs some focus might be given to this area. In a way the process of focusing on cost only is the same as bean counters being in charge of production changes. A better strategy would be to consider both issues when possible. If you don't believe me ask people that have to preform repairs on ICE and Electric vehicles., which increases cost of vehicle ownership . Really like your channel and have been watching for a long time.

[@traxxi2003]

I really appreciate you guys for making these videos showing us how our cars are made. What's your opinion on these types of cells. To me they look like the Lipo batteries used on RC drones. Can we expect these batteries to last for 200,000+ miles? Assuming they are properly taken care of?

[@nilsfrederking62]

Minute 11:37 those welds look horrible, one of them is not even properly connecting the parts.

[@2710Wandi]

Is this battery waterproof? I mean if we get flooding on the road, is it safe to continue if the the chasis exposed to water?

[@MrAdopado]

No, clearly they never thought that the car would ever have to drive through puddles and flooded roads from time to time. I'm glad you spotted it first. Best you get in touch to point this out to Hyundai engineers and to Munro Associates engineers because despite their extensive experience and qualifications they need someone to explain this issue to them. (I imagine it must just be good fortune that from all the millions of EVs from different companies across the world there has yet to have been a safety issue crop up... hey, wait a minute, maybe they all DID design their cars to be safe driving through water ... who would have guessed?)

[@phillyphil1513]

Q: I mean if we get flooding on the road, is it safe to continue if [the chassis] exposed to water? A: well Chet has already tested this and paid a heavy price for his bad decision making, however even if Hyundai told you it WAS safe, it begs the question why would you really want to...? (hint: since like carbon fiber Submersibles things can fail dramatically). of course then there's the long standing issue of how water and High Voltage electricity don't mix, everybody knows this.

[@NorthernEVexperience]

great video very informative

[@MunroLive]

Glad it was helpful!

[@xxwookey]

What is a 'thermal flow screw'? I suppose I should go back and find the ID4 battery pack teardown to find out. I'm guessing some kind of drill-cum-screw that you put in and it spreads the ali whilst cutting a thread? Maybe you [put it into hot ali so it's more malleable?

[@xxwookey]

As ever this was great, but I'd have liked a little more time on the module construction. I didn't fully understand what was meant by the Z-fold and pancake construction flavours, nor how the tabs are connected to the end pieces. I like this design though - it seems quite space and weight efficient, yet still fettlable. And keeping the coolant separate seems very neat. Maybe they can iterate down to 1-2mm of goop over time and some some weight and money.

[@michaelnefedov2267]

The CEO Cory returned the car dirty - and second reviewing team points out at the dirt he didn't bother to clean. Well done, guys!

[@darbyelliott2890]

Nicely done 👏

[@MunroLive]

Thanks 😁

[@hallkbrdz]

Why don't any of the OEMs use single--phase immersion cooling to simplify the thermal circuits?

[@rakkaphan1982]

is there some kind of membrane pressure and humidity relief ? i know that most car do have them. thanks.

[@vanookribelashvili]

Hello, we received a Hyundai Ionic 5 from America, the car doesn't charge and can you help us?

[@wr4st]

Can someone tell me how the rubber gasket act as pressure relief in case of thermal runaway?

[@jonphair389]

Two in Canada now got written off by insurance. Because of the cooling bottom. So not service able.

[@flolou8496]

What year of the IONIQ 5 does this battery pack breakdown apply too ? The 2022 model? the 2023 model? the 2024 model?

[@dancingrick9627]

I for one will lease the Ioniq 5 over a Tesla. The 800 volt charging and easier access for battery maintenance seems to be a no brainer. Now that the 2025 can also charge on NACS without an adapter, just seems to me to be another win. Also when the Georgia plant comes online, the $7,500 rebate will kick in on sales of the Ioniq. I think there are a lot of trolls and ICE advocates commenting here, which saddens me. The US is already lagging the rest of the world in EV acquisition… as stubborn and divided as the US is, EVs are the future.

[@ryandoyle4344]

Great video. I may have misaed these. Will the fusible links create additional failure/service points? Does a link failure incapacitate the vehicle?

[@Somethingaboutthat]

Looks like it’d only affect part of the pack. Maybe 1/8th?

[@KiwiMechEng]

Certainly, but if a link fuses you may bigger problems to worry about.

[@USA-GreedyMenOfNoIntegrity]

7:40 are you sure that is not MIG welding?

[@Stefan_Dahn]

5:59 🔥🔥🔥 DO NOT leave your phone nor tablet computer in plain sunlight. This will heat up extremly fast and lead to a thermal runway, fire and explosion(s)! 🔥🔥🔥

[@FuncleChuck]

any thoughts on the $~500 “low conductivity” coolant that apparently only lasts a few years?

[@BatterVswithAntonio]

Standard coolant has corrosion inhibitors to extend the life of the radiator system, the issue is when you get into very large surface area brazings, you use a lot more high fluoride flux (vs cooling channels for example) to prevent oxidation during brazing and that flux reacts with the silicate based corrosion inhibitors and forms a gel byproduct that will clog the system and cause over pressure leaks. A few flush cycles should get out the residual flux, but at this point, no one knows how many cycles are needed to reduce levels to the point where there is no further gelling. So, yes, absolutely. Replace it after a while. Coolant companies have a few products out that are specifically formulated for EV applications.

[@KiwiMechEng]

The blue coolant is not used on the new Niro which also has an external cold sheet. It's not clear to me if Munro's Ioniq 5 has blue or pink coolant but I was under the impression that the expensive blue stuff is being phased out.

[@EV_OBD]

EV6 uses only standard pink coolant for battery and electronics.

[@MAGApepe]

nice,, wonder why they didnt put the cooling on the top ?

[@bronxtaskforce01]

Is there a way you folks can find or retrieve the Ioniq 5 vehicle that Hyundai quoted $60 grand in BC and redo the batteries yourself and show how much cheaper it is to service or repair?

[@yonallb]

The bedside hospital room table is super random. If I remember correctly there is a mirror that pops up if you slide out the tray. :P

[@BatterVswithAntonio]

Yes, the mirrors are still there

[@topev7864]

In regard to the Battery pack design to be service friendly when you’re building a product to break more often to create service work, then you build it to service friendly, If you’re building a component to last lifetime of the vehicles you don’t need to build it to be service friendly.

[@markplott4820]

TESLA battery pack, dont need to be Serviced.......lol.

[@patreekotime4578]

Its probably more to do with internal company politics. Traditional OEMs make most of their profits on selling parts to their licensed repair shops. So the ethos of repairability is more about making sure there are parts that *can be* repaired than making parts designed to fail. Tesla has shown that they arnt so much interested in repairing parts even when its obviously a faulty part from the factory. Its highly questionable whether that is something to hand out accolades for. And there is no such thing as designing parts that never need repair. ANYTHING can be broken and there seem to be some members of the general public who are out there trying to prove it.

[@bartwaggoner2000]

@@markplott4820 they are holding up pretty well, with little degradation over 200k miles - but unfortunately once you scrap the car there is little you can salvage

[@BatterVswithAntonio]

resiliency vs redundancy

[@nilsfrederking62]

@@patreekotime4578 Model 3 and Y are very reliable, lots of them out there with high mileage and only minor service requirement.

[@hugegamer5988]

The serviceability is never mentioned in these videos. While the perimeter injection molded gasket is more expensive, it is far more preferable than gluing it down. Reducing fastener count might save money that isn’t passed down to the customer, but in todays world phones and laptops that are just a glued brick inhibit right to repair, increase waste and environmental costs, and are generally viewed as inferior by knowledgeable consumers.

[@ericplatzke]

Good video, thanks guys!

[@MunroLive]

You bet!

[@vinodpund1574]

Great explained battery pack really appreciate your helpful information. I am also working in battery technology last couple of year and had 15 years in power train casting design for product cost and performance enhance. Munro is doing really wonderful job.

[@fnordpol]

Is there anything known about how many Charging cycles such a LiPo Based Pack can have? For LFP it is 3000+ cycles, for NMC it ist 1600-2000+ cycles, for LIPO batteries I have 500 in mind but that would mean, from my calculating perspective, that those battery packs are a bit short lived in comparison.

[@talk2jesse]

This is an NMC battery.

[@James0u812]

Are the dealers allowed to replace individual cell modules?

[@aboyousefnader5352]

Could we have the data and BMS connection details

[@deacbeugene]

Looks like it is a prototype but brought to production without creating special pre-fabricated parts and automated assembly line. And Hyundai is charging around 60000 Canadian dollars for replacement pack, so no surprise, all made manually.

[@Stefan_Dahn]

When you hear the the bells ringing, it is (usually) time for the unique Munro spinach break, mandatory for each employee. This saves costs vs. using a crane or a six million dollar man or a bionic woman. 😉

[@FrankieShovels]

What's the service procedure for when you run over a cinderblock on the highway and get a hole in that cold plate? New $20,000 battery?

[@rkan2]

During warranty - probably... After warranty there will probably be alternatives unless you puncture further.

[@nilsfrederking62]

@@rkan2 I doubt any insurance will be willing to cover an EV with a damaged cooling plate. But for normal city use it will be very unlikely that something hits the bottom plate that hard; if you bottom out the car, then you will most likely have a problem.

[@teguhsantoso4438]

I5 user here in Indonesia, cinder block on highway is common here, my I5 is one of the casualties 😢. But local authorised dealer here is certified to repair it, total quote is $8,250, majority of it is the cooling plate at $3,600 and thermal paste at $2,250, and applied to the plate with $170 applicator. And yes those damn black flimsy FRP price is only $80 😅

[@MrDeceptacon88]

Hi what is the max. discharge rate of these cells? Thanks

[@eviljagtech]

I can see why damage to the pan causes such issues now, not a good design on an SUV that has the chance for large rocks. that air gap isn't going to be enough from what I have seen customers do.