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A cooling system of flat aluminum extruded sections divided uniformly into small chambers has the task of maintaining the battery’s high-performance operation over the long term. Heat is exchanged between the cells and the cooling system beneath them via a thermally conductive gel pressed beneath each cell module. In what is a particularly resourceful solution, the gel evenly transfers the waste heat to the coolant via the battery housing.
A strong surround frame and lattice-type aluminum structure that holds the cell modules is designed to protect the battery block. A substantial aluminum plate provides protection against damage from flying stones or curbs, for instance. These measures demonstrate how the Audi engineers have developed the batter and cooling systems with safety in mind. The weight of the battery system including the housing pan with intricate crash structures is roughly 700 kilograms (1543.2 lb). It is bolted to the underbody of the Audi e-tron at 35 points. This increases the torsional rigidity of the body, which in turn integrates numerous aluminum parts such as the floor plate in the rear structure, the doors, as well as the hood and tailgate. The cabin features components made from heat-formed ultra-high-strength steel.
Designed for efficiency and integration, the e-tron is engineered for both AC and DC charging via the widespread SAE J1772 and Combined Charging System (CCS) standards. In an industry first to-date, the e-tron debuts a DC fast charging capability of up to 150 kW available at select high-speed public charging stations, this capability can deliver up-to an 80 percent charge in only approximately 30 minutes. For customers’ residential charging needs, a standard 9.6 kW AC capsule charger (Level 2, 240-volt/40 amps) is provided and designed to deliver a fresh charge overnight. This charger will include plugs that can utilize both a standard 120-volt household outlet (1.2 kW) as well as a fast-speed 240-volt NEMA 14-50 outlet (9.6 kW).