Active Cooling Techniques for EV Battery Protection

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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Stackable battery modules for electric vehicles that can be joined together without fasteners or tools to form a stack, and that provide cooling without additional seals. The modules have interlocking features on their housings to center and secure the stack. The housing has a tongue and groove connection that engages with a corresponding feature on another module to create a cooling channel between them. The modules are inserted into a housing that seals against coolant loss. This allows coolant to flow through the channels between modules without needing separate seals.

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Electric vehicle cooling system using air cooling instead of liquid cooling for battery modules. The system has an air compressor, condenser, evaporator coils, blowers, and ducts to circulate cooled air through the battery packs. The evaporator coils are supported in side housings that house the battery modules. Blowers direct cooled air from the evaporator coils into the battery packs. One blower for each pack. This provides efficient cooling for the packs without requiring liquid cooling.

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Thermal regulation system for vehicle batteries that provides safe and reliable operation of high-power batteries in vehicles. The system uses a closed fluid network with a pump to circulate dielectric heat transfer fluid through the battery modules. Temperature sensors monitor the battery and the fluid. A control unit switches between free circulation, heating, and cooling modes based on sensor readings. This allows precise temperature control of the batteries without relying solely on ambient cooling or active cooling devices.

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Battery module for a vehicle that can detect thermal runaway early to prevent spread and fires. The battery module has a fluid monitoring device inside the housing to detect pollution fluids escaping from cells. It uses an electrical conductivity sensor to measure changes in the fluid conductivity caused by escaped cell fluids. If conductivity spikes, it indicates a cell failure and triggers selective thermal regulation to isolate and prevent spread. This allows diagnosing cell failures early without temperature sensors on each cell.

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Thermally conductive interface device for battery packs that provides efficient cooling, reliable electrical connections, and simplified manufacturing while minimizing weight, cost, and complexity. The device uses a thermally conductive silicone material with specific fillers and oils. The fillers are alumina and boron nitride, and the oil mixture is methyl silicone and methyl vinyl silicone. This composition balances thermal conductivity, compression set resistance, electrical insulation, and other properties for battery pack applications.

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Fan module with improved heat dissipation by reducing the gap between fans. The fan module has quick release brackets that attach to the fan and fan frame. The connectors between the fan and frame insert into each other. By making the connector projection on the frame bottom fall within the range of the bracket projection, it reduces the gap between fans compared to external cables. This eliminates ineffective cavities and improves overall airflow and cooling.

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Battery case for electric vehicles that improves cooling efficiency, reduces weight, and allows higher cell density compared to conventional battery cases. The case uses parallel cooling channels in the width direction of the vehicle instead of serially connected channels. This allows better thermal balancing by having batteries at both ends exchange coolant at the same temperature. Sealers separate non-cooling channels from cooling channels to prevent coolant leakage. The case uses extruded components like side members and cooling blocks for better rigidity vs pressed boards. The lattice structure with intersecting members reduces parts count compared to separate case pieces.

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Electric vehicle cooling system that efficiently cools components like batteries using a central air cooling system with multiple outlets to distribute cooled air throughout the vehicle. The system has a compressor, condenser, and evaporator coils. One coil cools the main battery pack, and a portion of the cooled air goes into the pack itself. Smaller coils cool side battery modules, and their air is directed into the main pack. The pack airflow path has partitions to channel the main coil air through the pack in a zigzag, exiting through the returns. This provides more air volume through the pack than side modules. The side module coils feed their air into the pack sideways. This unequal volume flow balances cooling needs while preventing excessive air volume in the pack.

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Battery module frame design to mitigate thermal runaway propagation in multi-cell battery packs. The frame has a partition member that partially separates the module into sections for each cell stack. The partition has a cavity filled with a heat absorbing agent. If a cell stack goes into thermal runaway, the heat absorbs and prevents propagation to the other stack. Alternatively, the partition has a coolant conduit and valve. If a stack goes into runaway, a thermal runaway detector activates the valve to flood the partition with coolant to suppress runaway spread.

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