Active Cooling Techniques for EV Battery Protection

ABSTRACT Heat generation during fast charging and discharging of lithiumion batteries (LIBs) remains a significant challenge, potentially leading to overheating, reduced performance, or thermal runaway. Traditional battery management systems (BTMS), such as airbased cooling indirect liquid using cold plates, often result in high gradientsboth vertically within cells horizontally across packsespecially under highcurrent discharge rates. To address these issues, this study introduces evaluates steadystate convectionbased esteroil immersion (EOIC) technique for LIBs. Numerical simulations based on the Newman, Tiedemann, Gu Kim model, aligned with multiscale multidimensional principles, were performed both single 18650 cylindrical cell 4S2P pack. Experimental validations conducted 2C 3C rates at 25C ambient temperature. The EOIC system demonstrated temperature reduction up 13C 15C pack compared natural air convection achieved 10C gradient simulation results closely matched experimental data, maximum deviation only 2C, confirming model's reliabi... Read More

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Battery system with improved thermal management to increase efficiency, cell life, and uniformity. The system has a cell holder with a fluid circuit through the cell stack obstructed by the cells. An unobstructed fluid circuit runs alongside the stack. Valves allow controlling fluid flow to the cell stack vs. side channel. This allows separate cooling/heating of the stack vs. side channel. For example, a non-dielectric fluid can circulate around the cells during low load, while a dielectric fluid circulates inside the stack during high load. This provides flexibility in fluid selection and flow distribution for optimal thermal management.

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Thermal management system for electric vehicle battery packs that provides efficient cooling and heating without adding significant weight or cost. The system uses a network of flexible tubes connecting intake and exhaust manifolds with channels tuned for even fluid flow distribution. It allows direct contact cooling/heating of individual battery cells by conforming tubes passing between them. The system connects to a pump and heat exchanger for circulating fluid through the pack. The flexible tubes fill and bleed easily for installation. The manifold design prevents fluid bypassing and ensures full inflation.

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Improving safety and reliability of battery packs by selectively supplying power to the cooling system when a thermal runaway occurs in one module. When a battery module undergoes thermal runaway, the system determines the module and surrounding modules without runaway based on voltage levels. It then powers the chiller using the non-runaway modules to cool the pack. This prevents overheating and gas generation in the runaway module. The vehicle control unit assists by checking the power supply circuit of the backup modules.

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Battery thermal management systems (BTMS) ensure the safety and performance of lithium-ion batteries, which power electric vehicles. However, designing an effective BTMS is challenging due to batteries' complex behaviour sensitivity temperature variations. This review comprehensively explores current vital technologies trends in BTMS, explicitly focusing on analysing various cooling control strategies. To discuss four primary technologies: air cooling, liquid immersion phase change material (PCM) cooling. The advantages disadvantages each technology are compared terms cost-effectiveness, applicability, limitations when dealing with high-energy-density batteries. Furthermore, delves into discussion strategies data prediction methods for emphasizing importance advanced analysis optimising battery safety. Different strategies, such as passive, active, hybrid control, introduced evaluated. Data methods, artificial neural networks, fuzzy logic, machine learning, also presented discussed. comprehensive provides in-depth understanding while serving a valuable reference future research appli... Read More

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Electric vehicles (EVs) are pivotal in reducing greenhouse gas emissions and achieving sustainable transportation goals. However, lithium-ion batteries (LIBs), the primary energy source for EVs, face critical thermal management, safety, long-term efficiency challenges. This study proposes an integrated battery management system that combines a waterethylene glycol-based liquid cooling mechanism with high-conductivity copper tubing to enhance LIB performance, longevity, safety. Through COMSOL multiphysics simulations, this examines behavior under varying operational conditions. The results indicate 20% reduction temperature peaks, maintaining optimal range of 15C 35C, thus mitigating risks runaway. Experimental validation using infrared thermography imaging confirms system's efficiency, showing maximum recorded 43.48C load conditions, significantly lower than unmanaged systems. Beyond work integrates advanced strategies, including state-of-charge estimation, predictive fault diagnostics, active optimization, cell balancing. analysis further reveals proposed improves heat diss... Read More

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Abstract With the rapid development of liquid cooled charging technology, thermal management gun electric vehicle has also become an urgent challenge to be solved. In this paper, accurate simulation model is developed by correcting conductivity and heat generation through integration experimental results. Subsequently, experiment designed with current, coolant inlet flow, temperature, ambient temperature as variables, from which a series results are obtained. Utilizing these training set, reduced order for predicting established. The influence multi-layer perceptron model, response surface gaussian process on prediction accuracy then compared. indicate that compared other two models, more significant advantage in fitting nonlinear average error 1.61 C. This study holds importance intelligent devices.

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Battery system with improved cooling and thermal management for preventing thermal runaway propagation. The battery system has cell spacers between the cells, a gap filler layer between the spacers and the cells, and a cooling plate behind the gap filler. The cell spacer fin penetrates the gap filler and contacts the cooling plate to provide a direct heat path. This allows rapid dissipation of cell heat to the cooling plate, preventing runaway spread. The fin penetration is achieved by pressing it into the gap filler.

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To address the issue of over-regulation temperature a liquid-cooled power battery thermal management system under plowing condition electric tractors, which leads to high energy consumption, nonlinear model prediction control (NMPC) algorithm for tractors applicable is proposed. Firstly, control-oriented tractor heat production and transfer were established based on operating conditions Bernardis theory production. Secondly, in order improve accuracy prediction, method future working information moving average Finally, predictive cooling optimization strategy proposed, with objectives quickly achieving regulation reducing compressor consumption. The proposed validated by simulation hardware-in-the-loop (HIL) testbed. results show that NMPC can better, holding phase reduces speed variation range 24.6% compared PID, it consumption 23.1% whole phase.

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A plug design for sealing cooling channels in electric vehicle battery box floors. The plug has an inner piece that contacts the coolant and an outer piece that attaches to the frame. The inner piece is less stiff than the outer piece. This allows the inner piece to adapt to the channel shape while the outer piece provides rigidity for insertion and positioning. The two-piece plug configuration allows easy sealing of the cooling channels in the battery box floor.

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Battery module with enhanced thermal management through strategically integrated phase change materials (PCMs) that absorb heat generated in critical battery connections. The module features a bus bar with integrated phase change members that distribute heat from connecting areas between the cell tab and bus bar, while a secondary phase change member is positioned on the top surface of the cell. This dual-phase design enables targeted cooling of high-temperature areas, particularly the connecting region between the cell tab and bus bar, while maintaining overall system thermal balance. The phase change materials are designed to absorb and release heat efficiently, preventing thermal runaway and fire hazards.

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Electric vehicle power supply layout to improve cooling and ripple current absorption. The power supply components like inverters are arranged in an alternating pattern of power cards and link capacitors along a main axis. This interleaving improves cooling by creating channels between the components for airflow. It also reduces ripple currents by absorbing them in the link capacitors and isolating them from the power cards.

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Energy and thermal management system for fuel cell vehicles that optimizes performance and longevity by proactively cooling the fuel cell and battery in anticipation of increased load demands. The system uses route prediction to identify sections with expected high fuel cell loads. It then lowers the fuel cell temperature ahead of time to improve power density and prevent overheating during peak demand. It may also cool the battery, reduce maximum fuel cell power, increase battery charge, and adjust power split to further manage energy use.

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A heat exchanger design for cooling batteries in electric vehicles that provides more uniform cooling compared to traditional heat exchangers. The heat exchanger has two main flows, one for cooling the battery and another for circulating refrigerant. The refrigerant flow has multiple paths that branch and reconnect, allowing the refrigerant to move in parallel between the battery and the main flow. This creates a more complex flow path that promotes more uniform heat transfer between the battery and the refrigerant, which helps prevent hot spots and improves cooling efficiency.

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A movable battery system for electric vehicles that enables independent charging, discharging, and thermal management of auxiliary batteries. The system comprises a separate battery pack mounted on the auxiliary vehicle, with its own cooling system and power management components. A thermal management module and power conversion module are integrated into the main vehicle's battery pack, while the auxiliary vehicle's battery has its own cooling system and thermal management components. The system allows the auxiliary vehicle's battery to be charged and discharged independently of the main vehicle's battery, with its own cooling and thermal management systems.

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Battery pack design with improved cooling to prevent overheating and degradation of the battery cells. The pack has a heat pipe adjacent to each cell that absorbs and conducts the cell's heat. A cooling device circulates a fluid through the heat pipe to extract the heat. The heat pipe has a chamber with wick structure and pillars. The chamber is partitioned into multiple sections with different numbers of pillars adjacent to the cell versus the other sections. This allows preferential flow of fluid through the section closest to the hot cell, enhancing heat transfer.

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Cooling system for electric vehicle battery packs that provides enhanced cooling for high performance vehicles with high power density batteries. The cooling system uses cooling jackets that wrap around the battery cells in multiple surfaces to increase the overall cooling area. This allows simultaneous cooling of both the main cell faces and the end faces. The jackets have contiguous passages that fluidly connect to promote simultaneous cooling of multiple cell surfaces. The jackets can also have turbulators, fins, and manifolds for improved cooling performance.

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Air flow-based cooling device for improving cooling efficiency of heat-generating objects and reducing cooling energy consumption through convective circulation cooling achieved by airflow control. The device involves a vertical cell stack with cells containing heat-generating objects. An intake pipe generates vertical airflow into the cells, which is then distributed horizontally. A discharge pipe extracts horizontal airflow from the cells, generating vertical flow. This creates a circulating airflow through the cells. The cell stack, intake pipe, and discharge pipe are detachable for flexible maintenance and expansion.

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Electric vehicle cooling system with distributed liquid cooling to effectively cool components like the inverter, motors, charger, and battery packs. The system has multiple coolant loops with pumps and a central radiator on the roof. Components like the inverter and motors have dedicated loops, while components like the charger and secondary converter share a loop. This allows parallel cooling paths to simultaneously cool multiple components. The radiator is mounted on the roof for efficient heat dissipation. The loops connect at couplings between the radiator and pumps.

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Battery system for vehicles and other applications with regulated battery temperature control to improve performance and prevent damage. The system has a battery unit with an internal heat exchanger, an external heat exchanger connected to a coolant circuit, and a temperature controller. The temperature controller regulates the coolant flow through the external heat exchanger based on the battery temperature. This allows actively cooling or heating the battery unit by circulating coolant through the external heat exchanger. This provides precise temperature control for optimal battery operation and protection.

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