In the continuous iteration of new energy vehicle technology, the role of automotive pipes has long transcended that of a simple "conveyance channel". Innovations in their material selection and manufacturing processes are becoming a vital force driving improvements in overall vehicle performance. The upgrading path of pipeline systems, from traditional fuel vehicles to new energy vehicles, reflects the automotive industry’s unremitting pursuit of safety and lightweight design.
Early automotive pipes were mostly made of metal materials such as steel and copper, which dominated the fuel vehicle era due to their high strength and corrosion resistance. However, in the field of new energy vehicles, the limitations of metal pipes have gradually emerged—their heavy weight and insufficient assembly flexibility make them unable to meet the demands for vehicle lightweighting and complex layout.
Today, automotive pipe materials are developing in a diversified direction. High-pressure hydrogen pipes adopt high-pressure-resistant carbon fiber composites, which are made by combining carbon fiber with a resin matrix. Their strength is comparable to that of metal, but their weight is only 1/4 of that of steel of the same volume, with extremely low hydrogen permeability. This makes them suitable for hydrogen fuel cell vehicles’ requirements for high pressure, light weight, and leak prevention. Data from a hydrogen energy vehicle manufacturer shows that after adopting carbon fiber composite pipes, the overall weight of the hydrogen storage system was reduced by 30%, and the cruising range was increased by approximately 15%.
In coolant pipes and refrigerant pipes, high-performance engineering plastics have become the preferred choice. For example, PA66 (polyamide 66) added with glass fiber can withstand temperatures above 150°C, has excellent impact resistance, and good flexibility. It can be flexibly bent according to the vehicle layout, reducing the number of joints and lowering the risk of leakage. In the battery cooling circuits of pure electric vehicles, the application rate of such plastic pipes has exceeded 80%, which not only reduces the vehicle weight but also lowers manufacturing costs.
Traditional pipe manufacturing processes such as welding and bending are gradually being replaced by more advanced technologies to meet the high-precision requirements of new energy vehicle pipes. The application of laser welding technology has elevated the sealing performance of pipe joints to a new level. Weld strength is 20% higher than that of traditional arc welding, and the heat-affected zone is small, avoiding performance degradation caused by high-temperature deformation of pipes. This is particularly suitable for connecting high-pressure brake pipes and hydrogen pipes.
3D printing technology has opened up new possibilities for manufacturing complex pipes. For electronic control system cooling pipes with special shapes and complex internal flow channels, 3D printing enables integrated molding, eliminating multiple splicing steps and reducing fluid resistance. A new energy vehicle manufacturer used 3D printing to produce motor cooling pipes, which improved the smoothness of internal flow channels by 40% and heat dissipation efficiency by 12%, effectively solving the overheating problem of motors during high-speed operation.
In addition, pipe surface treatment processes are constantly upgrading. For battery coolant pipes, inner wall smoothing technology is adopted to reduce frictional resistance during liquid flow and improve heat dissipation efficiency. Pipes exposed under the vehicle are coated with corrosion-resistant layers to resist erosion from rain, snow, and salt, extending their service life to more than 1.5 times that of traditional pipes.
As new energy vehicles become more intelligent, automotive pipes are moving toward "functional integration". The pipe systems of some high-end models have integrated sensors that real-time monitor parameters such as pressure, temperature, and flow inside the pipes, and transmit data to the vehicle control system. When abnormal pipe pressure is detected, the system can issue warnings in a timely manner or even automatically cut off relevant circuits to avoid safety accidents. In hydrogen fuel cell vehicles, the response time of pressure sensors in hydrogen pipes has been shortened to 0.1 seconds, enabling rapid detection of tiny leaks and triggering protection mechanisms.
The integrated design of pipes also plays a role in reducing vehicle space occupation. By rationally arranging battery cooling pipes, motor cooling pipes, and air-conditioning refrigerant pipes—through shared brackets and optimized routing—the space occupied by the pipe system in the vehicle can be reduced by 15%, freeing up more space for the arrangement of battery packs and motors. An integrated pipe solution from a vehicle manufacturer reduced the number of underbody pipes by 25% and shortened assembly time by nearly 1/3, significantly improving production efficiency.
From materials to processes, from single functions to intelligent integration, every upgrade of automotive pipes is closely linked to the development needs of new energy vehicles. They are not only the "connectors" of various vehicle systems but also the "carriers" of technological innovation. In improving vehicle safety, economy, and cruising capability, they continue to contribute irreplaceable strength, serving as a solid foundation for the high-quality development of the new energy vehicle industry.
