Active Cooling Techniques for EV Battery Protection

Optimizing energy management of an energy storage system (ESS) connected to a renewable energy source and grid to improve performance and prolong life. The ESS contains multiple energy storage units. Charging and discharging strategies are determined based on renewable generation, grid power, and ESS state info, including time spent in depth of discharge (DOD) ranges. This allows flexible, prioritized ESS charging/discharging to balance grid needs, avoid over/undercharging, and reduce cycling.

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A heat pump system for vehicles that uses natural refrigerant like carbon dioxide instead of synthetic refrigerants like R134a to improve environmental friendliness. The system has an air conditioner unit with a compressor and heat exchangers, and a chiller that exchanges heat between the refrigerant and coolant to adjust the coolant temperature. The chiller can be used to efficiently cool the vehicle battery. The natural refrigerant allows higher pressure and temperature operation for better cooling/heating performance compared to synthetic refrigerants.

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A heat pump system for vehicles that uses natural refrigerant like carbon dioxide (R744) and a single chiller to cool/heat the cabin and battery pack efficiently. The system has an air conditioner unit with a compressor, heat exchangers, and a control valve. It connects to a chiller that exchanges heat between the refrigerant and coolant. The control valve isolates the chiller from the cabin side during full cabin cooling. This allows the chiller to focus on battery cooling when needed. The R744 natural refrigerant provides better cooling/heating performance in the supercritical region.

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Simplified and efficient thermal management system for electric vehicles that uses a heat pump instead of multiple fluid loops and separate heaters. The system has a single refrigerant loop with a compressor, condenser, exp valve, and chiller. The coolant loop has 2 pumps, valves, cooler, heater, battery, and drive module. The control module regulates refrigerant, coolant, airflow, and heater to heat/cool cabin, battery, and electronics. The heat pump dehumidifies cabin air, cools cabin/battery at high temps, and cools electronics. This simplifies architecture vs separate loops/heaters.

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Converting regenerative braking energy in an electric vehicle to prevent battery degradation without side effects like uncomfortable air conditioning operation during regenerative braking. The method involves a battery chiller connected between the battery coolant loop and the air conditioning refrigerant loop. During regenerative braking, if the battery charge level reaches a threshold, the air conditioning compressor is run to consume the excess regenerative energy. The 4-way valve switches the refrigerant flow to either condenser or radiator in the chiller based on the battery cooling or warming mode. This allows continuous conversion of regenerative energy through the compressor, independent of the passenger cooling/warming mode. The chiller absorbs/releases heat from/to the battery coolant as needed.

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Battery box design for electric vehicles that improves thermal management and reduces temperature differences between battery cells. The battery box has side plates and a bottom plate with internal partitions to form multiple flow channels. The cooling liquid flows through the channels all in the same direction, which provides uniform cooling to the cells in a perpendicular direction compared to the traditional U-shaped flow path. This improves heat exchange uniformity and reduces cell temperature variations.

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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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