Active Cooling Techniques for EV Battery Protection

Power storage device with improved cooling efficiency for stacked batteries. It has a power storage module with cells sandwiched between a thermally conductive layer and a cooler above. The cooler has flow paths extending into each cell. The connecting portions between the paths bend easier than the paths. This allows following cell height variations without thickening the conductive layer. It also has options like insulation under bends and bidirectional flow paths for uniform cooling.

Source

A cooling control system for electric vehicles that predicts cooling needs and overcools components to prevent overheating during operation. The system monitors vehicle characteristics like future power demands, thermal data, and navigation info to anticipate component heat levels. It generates a cooling command based on these predictions to proactively lower component temperatures. This allows the vehicle to maintain optimal operating ranges by overcooling components before they reach critical temperatures.

Source

A compact, integrated thermal management system for vehicles that reduces weight, complexity, and packaging compared to conventional systems. The system uses a component housing unit that attaches to the expansion tank. The unit has separate flow channels for connecting components like batteries and pumps to the thermal loops. This allows integrating the components directly into the loops instead of having separate external loops. The housing also has a valve to select parallel or series loop flow. The expansion tank connects to both loops through the housing. This integrated design simplifies the system with fewer components, reduces weight, and allows compact packaging.

Source

Fluid collector for battery thermal management that improves heat exchange uniformity and reduces thermal runaway risk. The collector has a housing with a fluid chamber connected to the battery's heat exchange channels. It also has a separation portion inside the chamber that divides it into concave cavities. Each cavity communicates with at least one channel. This series connection improves heat exchange uniformity compared to parallel channels.

Source

Thermal management system for electric vehicles that can efficiently cool high-power batteries and motors to enable fast charging and high performance. The system has separate loops for battery and motor cooling. The motor loop can bypass the condenser for higher flow rate cooling when needed. This allows satisfying cooling requirements for high-power motors under fast charging conditions. A switch element can open/close the bypass to balance cooling between loops.

Source

Integrated thermal management system for electric vehicles that uses a heat pump unit and a thermal management unit to efficiently regulate the temperatures of the battery pack, electrical components, and cabin air conditioning. The system uses a refrigerant-cooled water heat exchanger to transfer heat between the refrigerant and water. This allows the water to be selectively routed to the battery pack, components, and air conditioner based on driving conditions. The system has valves to adjust refrigerant and water flow patterns for optimal thermal management modes.

Source

Battery pack design for electric vehicles with improved thermal management and safety. The pack uses a double-layer configuration with two battery modules stacked together. Cooling plates are attached to the top of each module. This allows effective liquid cooling of both modules during operation. The pack also has relief cavities connected to explosion valves and pressure relief channels to prevent gas leakage if cells overheat. The relief cavities isolate pressure buildup to avoid affecting other components.

Source

A thermal management system for electric and hybrid vehicles that efficiently controls temperatures of vehicle components like the battery, powertrain, and cabin while reducing packaging size and cost compared to separate systems. The system uses a flexible thermal unit (FTU) that integrates components for controlling coolant and refrigerant flow between systems like the battery, drivetrain, and cabin air. This allows thermal management of multiple subsystems from a single device, reducing packaging requirements and costs while increasing function and performance.

Source

Battery cooling system for electric vehicles that improves cooling performance without increasing occupant discomfort from fan noise. The system adaptively adjusts fan speed based on window state. When windows are closed, it uses lower fan speeds for lower battery temperatures to avoid excess noise. When windows are open, it allows higher fan speeds for lower temps to compensate for external airflow. This prevents overcooling with closed windows and allows sufficient cooling with open windows without excess fan noise.

Source

Battery-integrated heat pump system that reduces efficiency losses and keeps batteries at optimal temperatures. The system uses a direct current (DC) power source like solar panels and batteries. Instead of converting DC to AC then back to DC, the compressor and fan speeds are directly controlled by a variable speed drive that receives DC power. The fan moves air across the battery surface to regulate temperature. This avoids the efficiency loss from multiple conversions. The battery is located in the airflow path to maintain optimal temperature.

Source

A novel architectural design is proposed to mitigate uneven thermal distribution, peak temperature, and heat spot generation, which are common issues that observed in conventional battery packs. This approach features a multi-terminal configuration, incorporating modified pack structure along with switching algorithm identifies the optimal terminal for current flow load. In design, first second terminals placed at fourth series string while divided into four regions, each corresponding one string. Additionally, points represent zones level. Experiments were conducted evaluate performance of dual-terminal mechanism three configurations1S, 2S, 3S. The 1S setup outperformed single-terminal achieving 6.23% improvement reducing zone temperature difference (Pz). 2S configuration demonstrated an 11.11% improvement, 3S achieved region (Pr) >50%, without cooling system. Finally, forced air effectively lowers it insufficient addressing distribution formation. However, integrating enables effective control management all critical parameterspeak generation.

Source

The enhancement of phase change materials (PCMs) through the incorporation nano-additives presents a promising approach to overcome intrinsic limitations in thermal conductivity and energy storage capacity, thereby advancing management technologies. This chapter provides comprehensive analysis thermophysical chemical properties various nanoparticles their synergistic interactions within PCM matrices. Emphasis is placed on role nanoparticle morphology, size distribution, surface functionalization optimizing heat transfer efficiency transition dynamics. critical evaluation dispersion stability long-term performance under cyclic conditions discussed. Environmental safety considerations, alongside evolving regulatory frameworks, are examined address sustainable integration nano-enhanced PCMs into practical applications. also highlights emerging algorithmic pedagogical strategies monitor, manage, mitigate potential ecological occupational risks. By bridging material science, environmental stewardship, policy development, this work establishes holistic foundation for future design deployme... Read More

Source

Efficient thermal management of lithium-ion batteries is crucial for electric vehicle safety and performance. This study investigates immersion cooling in serpentine channels 18650 batteries, aiming to identify key factors affecting maximum battery temperature (Tmax) pump power (Pw). A Box-Behnken experimental design implemented with Computational Fluid Dynamics simulations analyze responses Tmax Pw. Five variables are defined: partition length (Lp), charging/discharging rate (Crate), coolant volumetric flow (V), inlet (Tin) ambient (Tamb). Statistical significance evaluated via Analysis Variance. The results show that: Tin dominated Tmax, followed by Crate, V, Lp. Significant interactions (VTin VTamb) observed. For Pw, V V extreme significance, while Lp effects were minor. Interaction LpV was significant but secondary. After optimization minimize Tave the optimal values Lp, Tin, Tamb determined be 89.5 mm, 1.08 C, 0.51 LPM, 20 C, 25.62C respectively. corresponding optimized are: = 22.87C, 21.67C, Pw 0.279 mW. Optimal requires prioritizing control suppression regulati... Read More

Source

Abstract Large prismatic cells are increasingly being used as the primary power source in transportation applications. Effective online thermal management of these is crucial for ensuring safety and maximizing performance. However, significant discrepancies between surface internal temperatures make it difficult to detect anomalies promptly, which hinders effective increases risk irreversible hazards. This paper introduces an innovative technology Liion batteries. By exploiting temperature sensitivity ultrasound velocity applying tomographic reconstruction based on surrounding measurements, enables detailed crosssectional imaging. allows nondestructive, realtime visualization temperatures. Furthermore, with its compact design costeffectiveness, this suitable insitu deployment, offering a precise feedback mechanism management. Demonstrations conducted during continuous discharging scenarios have shown that system can identify hightemperature regions near tabs remain undetected by thermocouples. advancement has potential significantly reduce fires or explosions whi... Read More

Source

This study presents an experimental investigation of a novel hybrid battery thermal management system (BTMS) that integrates solenoid-actuated Peltier-based heat sink with CuO/ethylene glycol (EG) nanofluid coolant loop. The delivers on-demand cooling through time-controlled thermoelectric operation, enhancing temperature regulation during surges. Experiments were conducted CuO nanoparticle concentrations ranging from 0.5% to 2.0% (vol.) and flow rates 1 5 LPM, at inlet 50C ambient 26C. Performance metrics such as drop, transfer rate, overall coefficient analyzed. Results showed maximum enhancement 40.63% (tube-side) 38.64% (air-side) CuO. Compared conventional liquid system, the setup demonstrated 7.01% higher rate improved variation control (up 28.53%). Life Cycle Cost (LCC) analysis demonstrates 25%30% reduction in long-term costs 36% life extension, supporting systems economic viability. scalable, energy-efficient BTMS offers promising solution for advanced electric vehicles requiring high-precision control.

Source

Battery cooling system for electric vehicles that prevents delays in cooling the battery pack when switching from cold to hot environments. The system uses a thermosiphon cooling circuit with condensers and coolers. If circulation stops due to liquid filling the circuit, it enters a vapor phase temperature rise control mode. This raises the condenser temperature to lower the liquid level, allowing circulation to restart sooner than waiting for natural evaporation. It also uses higher target refrigerant temperatures during circulation restart to further lower liquid levels. This prevents the condenser and coolers from fully filling with liquid when switching environments.

Source

Recently, electric vehicles (EVs) have proven to be a practical option for lowering greenhouse gas emissions and reducing reliance on fossil fuels. Lithium-ion batteries, at the core of this innovation, require efficient thermal management ensure optimal performance, safety, durability. This article reviews current scientific studies controlling temperature lithium-ion batteries used in vehicles. Several cooling strategies are discussed, including air cooling, liquid use phase change materials (PCMs), hybrids that combine these three types with primary objective enhancing performance batteries. Additionally, challenges proposed solutions battery pack design energy methodologies explored. As demand increases, improving systems (BTMSs) is becoming increasingly important. Implementing developing better BTMSs will help increase autonomy safety long term.

Source

A thermal management system for electrified vehicles that efficiently manages heating and cooling of the battery and cabin using a combination of a glycol system and a refrigeration system. The system has valves to connect and isolate loops for the battery, power electronics, radiator, and cabin heating. By separating components of similar operating temperatures and allowing heat transfer between them, it reduces energy consumption and hardware compared to a single system. The glycol system actively heats the cabin, while the refrigerant system actively chills the battery and power electronics. Valve configurations allow optimization under different vehicle conditions.

Source

Battery module design for electric vehicles that improves cooling efficiency, reduces weight, and simplifies assembly compared to conventional battery packs. The module uses a horizontal cooling plate below and thermally conductive adhesive to bond pouch-type secondary batteries. This direct contact cooling provides better heat transfer than stacked cartridges. The adhesive secures the batteries without fasteners or cartridges. The design reduces module size and weight by eliminating cartridges and fasteners. It also allows closer battery spacing for improved cooling. The adhesive bonding ensures stable battery positioning without cartridge movement issues.

Source

Thermal regulation device for electronic components like batteries that overheat during charging or operation. The device has a housing with a condensation wall that promotes condensation of a dielectric fluid sprayed onto the component. The condensation wall has relief features to increase surface area for condensation and microscopic channels to aid liquid evacuation. This allows efficient cooling as the dielectric fluid vaporizes on the hot component and condenses back on the wall.

Source