Active Cooling for EV Battery Protection

Battery module for electric vehicles that has a secondary cooling system to quickly and effectively cool individual cells with thermal runaway to prevent catastrophic failures. The module has two coolant circuits, one inside the module and another connected to an external refrigeration unit. The internal circuit has a heat exchanger that cools the cells. If a cell overheats, the internal heat exchanger is activated. If it still overheats, the external circuit is activated to bring the cell temperature down faster. This prevents thermal runaway propagation and cell damage.

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Lithium battery pack cooling system that equalizes temperatures across batteries in a pack to improve lifetime. The system uses independent pumps and temperature sensors on each battery's cooling channel. A controller adjusts pump flow rates based on sensor readings to balance temperatures. This prevents high middle battery temps and low outer temps. By dynamically regulating cooling flow, it keeps pack consistency and prevents hotspots.

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Thermal management system for vehicles with improved efficiency and versatility compared to traditional systems. The system uses separate heat exchangers to exchange heat with the battery at different efficiencies based on battery temperature. This allows optimized heat transfer without wasting energy on unnecessary heating or cooling. A controller manages the heat exchangers. The system also includes an air conditioning loop and options for heat storage. The separate heat exchangers and controller allow more flexible and efficient battery heating/cooling compared to a single heat exchanger.

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An active liquid cooling system for electric vehicle battery packs using high thermal conductivity aluminum cold plates with unique design features to improve cooling performance, uniform temperature distribution, and avoid thermal runaway. The cold plates have a height of 30-60 mm and a contact angle of 120-150 degrees between the plates and battery cells. This design lowers the highest pack temperature, provides uniform cooling, and handles rapid discharge and load changes. The increased plate height and angle in the flow direction enhances cooling by lowering temperature gradients and providing more surface area.

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Battery thermal management system that integrates phase change materials, thermoelectric cooling, and liquid cooling to efficiently dissipate and preheat the battery pack in both hot and cold environments. The system has a core control module, temperature sensors, power supply module, thermoelectric module, and liquid cooling module. It switches between three working modes: refrigeration, shutdown, and heating based on battery temperature. In hot environments, the thermoelectric module cools the pack. In normal temps, the module stops. In cold, the module switches current direction to preheat. The power supply adjusts flow rate based on module heat capacity. This adaptive mode switching meets cooling/heating requirements in varying temps.

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Thermal management system for fast charging electric vehicle (EV) battery packs to improve charging speed, battery life, and safety. The system has a pump, tubes, and control unit to circulate cooling fluid around the battery pack during fast charging to prevent overheating. The control unit monitors battery parameters like temperature, charge level, and aging. It calculates optimal charging current and temperature based on the battery condition. This ensures safe, efficient, and extended battery life compared to constant high charging rates.

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Battery thermal management system for electric vehicles that improves temperature uniformity inside the battery pack. The system uses two cooling loops, one bypassing some components like heaters and radiators, to circulate coolant. A valve switches between loops. The bypass loop has lower pressure drop. Periodically switching flow direction in both loops further reduces temperature gradients.

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Battery thermal management system for electric vehicles using immersion cooling to efficiently cool the batteries and prevent overheating. The system involves submerging the batteries in a non-conductive liquid, circulating the liquid to extract heat, and using an external heat exchanger to further dissipate it. This provides a closed loop immersion cooling system for the batteries. The liquid submergence and circulation prevents direct air cooling that can be less effective. The liquid cooling allows higher battery density and capacity without overheating.

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Battery thermal management system for electric vehicles that improves battery module output efficiency by using a closed-loop refrigerant cycle with heat recovery and regeneration. The system has a thermal management unit, cycle unit, heating unit, cooling unit, sensing unit, and control unit. The cycle unit circulates a first heat exchange medium to the battery module. The heating unit transfers refrigerant from the compressor to heat the battery. The cooling unit transfers refrigerant from the evaporator to cool the battery. The control unit selectively opens/closes the heating and cooling units based on battery temperature. This allows regenerating heat from the cooling unit to heat the battery instead of wasting it. The refrigerant cycle also allows separate cooling/heating paths to share pipes for simplicity.

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A locally controllable active power battery temperature control system to balance temperature within battery packs in electric vehicles. It uses dual cooling systems, one on each side of the battery module, along with a bottom cooling system. Electronic expansion valves on the parallel coolant pipes allow flow rate adjustment. By increasing flow in hot areas and decreasing flow elsewhere, it dynamically balances temperature throughout the battery pack without affecting total flow. This prevents uneven temperature differences during charging/discharging that can degrade battery performance and life.

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Active battery pack cooling system for electric aircraft that uses a combination of active cooling with a coolant channel and passive heat transfer elements to effectively cool the battery pack without excessive complexity and weight from fluid connections. The active cooling system has a coolant channel with a pump to circulate fluid. The passive elements extend from the coolant channel to individual battery modules to transfer heat passively. This limits the amount of active cooling needed. The active cooling is controlled by a temperature sensor to optimize performance.

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Thermal management system that allows easy implementation of a heat pump heating mode capable of simultaneous heat absorption during heating. The system includes a water-cooled condenser mounted on one of the cooling water circuits; a battery chiller mounted on another one of the coolant circuits and connected to the PE part to absorb heat; a water-cooled evaporator mounted on another one of the cooling water circuits and connected to a radiator to enable heat absorption; and a refrigerant circuit provided to circulate refrigerant from the water-cooled condenser to the battery chiller and the water-cooled evaporator.

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Thermal management system for high-capacity lithium ion battery packs that improves temperature uniformity and reduces energy consumption compared to conventional cooling methods. The system uses a liquid cooling plate, bidirectional pump, flow controller, water tank, and flat heat pipes between battery cells. The liquid cooling plate has a symmetric flow channel for bidirectional circulation. The flat heat pipes between cells improve vertical heat conduction. The flow controller switches pump direction to balance cooling across the pack. This improves temperature uniformity compared to single-direction cooling.

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Battery thermal management system that integrates heat pipes and thermoelectric refrigeration for efficient and effective cooling and heating of battery packs. The system uses a heat pipe to transfer heat between the battery and a thermoelectric cooling sheet. This allows rapid heat dissipation when the battery gets too hot, and rapid heat transfer when the battery gets too cold. The system monitors battery temperatures and controls the thermoelectric cooling sheet and water pump to maintain optimal temperatures for battery performance and safety.

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Power battery pack with a cooling system that improves thermal management and safety. The pack has separate cooling channels for the top, side, and bottom of the cells. A temperature sensor on the side walls adjusts the flow rate of the cooling medium. Paraffin wax between the cells absorbs heat. This enables targeted cooling based on cell temperatures. It prevents direct contact of cooling fluid with the cells and isolates adjacent cells.

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A high-efficiency thermal management system for large-scale power batteries that provides flexible and efficient cooling and heating of battery packs without complex fluid loops. The system uses a combination of air, water, and heat pipes. It allows selective cooling and heating of the battery pack using a modular design. The battery pack has a cooling bellows that expands and contracts with temperature changes. Heat pipes connect the pack to a central cooling unit with air cooling, water cooling, and heating options. A constant temperature water tank, gas-liquid separator, electric heater, and control logic complete the system. It enables targeted cooling and heating of battery pack regions for temperature uniformity. The system reduces fluid consumption, simplifies design, and eliminates leakage risks compared to closed loops.

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A cooling system for managing temperatures in a battery pack of an electric vehicle to improve charging efficiency and battery life. The system uses a base plate with transverse members and a pump to circulate fluid through the battery pack. The fluid flows between the cells, removing heat from hot spots and distributing it evenly. The pump can also connect to external heat exchangers to further regulate temperatures. The fluid circuit and flow rate are controlled by a thermal management system based on cell and ambient temps.

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Thermal management system for electric vehicles that improves battery and motor cooling efficiency with a simplified design compared to conventional systems. The system uses existing air conditioning components and ducts to cool the battery and motor without additional heat exchangers or pumps. Valves and flow regulators connect the battery, motor, and air conditioning system components to selectively route heat transfer paths. This allows battery heat to be released to the air through the AC system or absorbed by the motor during high load conditions. It also allows motor heat to be released directly to the air or absorbed by the battery. The simplified design reduces component count and complexity compared to separate battery and motor cooling systems.

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Simplified thermal management system for vehicles like electric cars that improves cooling efficiency while reducing complexity compared to conventional systems. The system uses a single loop with components connected in series instead of separate loops for battery, motor, and cabin cooling. The loop has a compressor, pump, heat exchangers, and valves. The compressor and pump circulate refrigerant through the loop. The heat exchangers transfer heat from the battery and motor to the atmosphere. Valves control flow and enable modes like battery-only cooling. This simplified loop reduces components vs separate loops while still providing effective cooling.

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Battery thermal management device for electric vehicles that effectively cools and regulates the temperature of the battery pack to improve performance, longevity, and safety. The device uses a two-loop cooling system with a compressor, condenser, expansion tank, water pump, heat exchanger, and throttling element. The first loop circulates refrigerant through the condenser near the battery pack to extract heat. The second loop circulates water through a heat exchanger to absorb heat from the battery pack. This two-loop system allows independent temperature control of the refrigerant and water circuits to regulate battery temperature. A control unit manages the loops based on temperature sensors.

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