Air-Cooled Thermal Management for EV Battery Packs

Battery pack design to improve thermal management of the cells and bus bar by integrally coupling the cell holder and bus bar with a heat-conduction accelerating feature. The cell holder and bus bar are molded together, with a portion of the bus bar that connects to the holder having an enhanced thermal conductivity feature. This accelerated heat transfer quickly and effectively moves heat from the bus bar to the cell holder, which has a larger heat capacity. The heat is then dissipated through air exchange with the environment. This prevents overheating of the cells and bus bar by quickly transferring and dissipating heat.

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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.

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Vehicle thermal management system for electric vehicles that provides efficient cooling, heating, and battery temperature control. The system uses separate refrigerant and coolant loops to cool the cabin, components, battery, and charge rapidly. It integrates refrigerant components like compressor, condenser, and chiller with a coolant loop through the cabin, radiator, battery, and components. A valve allows selective coolant flow through the chiller and battery. This allows simultaneous cabin and battery cooling, separate battery cooling, and battery heat absorption modes. The refrigerant loop only absorbs heat from air and components. The coolant loop provides independent cooling, heating, and dehumidification. It also enables battery rapid charging without refrigerant. The system reduces compressor power, complexity, and cost compared to direct heat pump systems.

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Thermal management system for electric vehicle batteries that improves efficiency and functionality by allowing separate heat exchange paths for different regions of the battery. The system has a main battery heat exchanger with two trunks. One trunk exchanges heat with a first region of the battery, and the other trunk exchanges heat with a second region. A controller adjusts the heat exchange amounts based on battery temperature. This allows proper battery heating/cooling in different regions. It also connects the battery heat exchanger to the air conditioning loop for further heat exchange. This improves battery temperature control by leveraging the existing HVAC system.

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Cooling module for electric vehicles that uses a tangential-flow turbomachine with pivoting shutters to efficiently cool the vehicle's heat exchanger without obstructing airflow when not needed. The cooling module has a turbomachine with a bladed wheel and motor to create airflow over the heat exchanger. Pivoting shutters can block the turbomachine opening. An electric motor rotates one shutter, which pivots to transmit rotation to the others. This selectively closes the turbomachine when cooling isn't needed to prevent airflow obstruction. The pivoting shutters allow full heat exchanger surface area cooling with uniform airflow when the turbomachine is running, but prevent airflow blockage when the turbomachine is off.

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A cooling system for power storage devices in vehicles that can prevent overheating when cabin air is hotter than the device without using cabin air temperature sensors. The system stops the cabin air blower when conditions indicate cabin air is hotter than the device, to prevent further heating. Conditions are stopped vehicle, low device heat, blower on, and device temp rising. This prevents cabin air intake if the blower is running when the device is stopped, as that indicates cabin air is hotter.

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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.

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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.

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A good thermal management system for batteries is the key to solving potential risks such as runaway of and ensuring that work within appropriate temperature range. To resolve conflict between cooling efficiency input power in existing battery systems based on thermoelectric cooling, this paper proposes an optimization method layout devices. Using a multi-physics coupling numerical model, study focuses analyzing impact quantity devices current temperature. The optimal arrangement structure response characteristics are investigated from four aspects: maximum temperature, difference, difference uniformity, coefficient. research results show optimized capable reducing both pack, reduces consumption by 19.8%, effectively enhancing energy system.

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The study presents a thorough theoretical analysis of the thermal distribution in electric vehicle battery packs under different heating loads. A finite-element heat transfer model is developed COMSOL to simulate pack with 15 cylindrical lithium-ion cells integrated liquid-cooled support plates. C-rates, which define generation during charge-discharge cycle, are included model-in real case scenarios wherein 10 Ah generates outputs about 10.5 W, 25 and 54 W at 3C, 5C, 8C charge rates, respectively. Transient simulations display how temperature profiles evolve time reach quasi-steady states by input counterbalanced dissipation through convection. It also examines air convection performance as technique for cooling, revealing that while it cheaper simpler implement, less effective than liquid cooling. Other alternatives this regard, such use graphite foam, have been investigated concerning their ability achieve higher coefficients, thus enhancing load management greater rates charge. results illuminate importance optimized systems avert runaway EV ensure safety, efficiency, longevity. w... Read More

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Vehicle with separate cooling circuits for battery, air conditioning, and interior heating to prevent battery temperature affecting comfort. The vehicle has a battery with a dedicated cooling circuit, an air conditioning system with refrigerant, and an interior heating system with a separate coolant. The condenser in the air conditioning system exchanges heat between the refrigerant and the interior heating coolant. This allows independent cooling and heating without connecting the battery cooling circuit to the passenger compartment.

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A heat exchange apparatus for balancing heat dissipation and heat preservation of a heat-exchanged element like a battery pack in different temperature conditions. The apparatus has a housing with a first cavity for liquid cooling and a second cavity that can be ventilated or closed. An outer wall of the first cavity contacts the heat-exchanged element. A sealing element covers the second inlet and a second sealing element covers the second outlet. A drive component moves the sealing elements to switch the second cavity state. In ventilated mode, air circulates the second cavity to preserve heat. In closed mode, the second cavity is isolated to prevent external heat transfer. This allows adaptive heat management based on ambient and element temperatures.

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In the context of global energy transition, thermal management electric vehicle batteries faces severe challenges due to temperature rise and consumption under dynamic operating conditions. Traditional strategies rely on real-time feedback suffer from response lag efficiency imbalance. this study, we propose a neural network-based synergistic optimization method for driving conditions prediction management, which collects multi-scenario real-vehicle data (358 60-s condition segments) by naturalistic collection method, extracts four typical (congestion, highway, urban, suburbia) combining with K-means clustering, constructs BP (backpropagation network) model (20 neurons in input layer 60 output layer) predict speed next s. Based results, coupled PID control mechanism dynamically adjusts coolant flow rate (maximum reduction 17.6%), reduces maximum battery 3.8 C, difference 0.3 standard deviation fluctuation at ambient temperatures 25~40 C is 0.2 AMESim simulation experimental validation. The results show that strategy significantly improves safety system economy complex working pro... Read More

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A battery cabinet design for energy storage systems that allows efficient packing, fixing, and cooling of a large number of cells. The cabinet has multiple battery units stacked inside, each unit having cells arranged in a grid with a heat dissipation channel between them. The channels connect to external cooling systems. This allows uniform cooling of cells in each layer as well as overall, facilitating dense cell packing and fixing.

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Abstract In the context of intelligent manufacturing, accelerating innovation within Electric vehicle manufacturing industry necessitates an in-depth investigation into battery heat dissipation technology. Traditional methods relying on mathematical models struggle to provide real-time observations temperature changes. This study employs AMEsim,a simulation software, construct that examine differences and effectiveness various methods. Notably, PCM(Phase Change Material) cooling demonstrates a significant advantage in reducing maximum by 20%. Simulation analysis reveals PCM can decrease 20, thereby enhancing thermal management performance lithium-ion batteries, which is crucial for improving their overall safety.

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Battery pack, thermal management system, and control method for a battery pack that balances heat dissipation with waterproofing. The pack has sealed cavities with internal channels for active cooling using fans. Temperature sensors monitor cell groups. The control system adjusts cooling and charging based on cell temps.

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Battery thermal management system for electric vehicles that provides flexible cooling and heating options to improve battery performance and reliability. The system integrates both air and liquid cooling/heating into a single enclosure surrounding the battery packs. It uses a gas channel with a cold medium source for air cooling, a liquid channel with a heat source/sink for liquid cooling/heating, and a temperature control component for further heat management. This allows adaptive cooling/heating based on ambient conditions and battery needs.

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Battery pack design with active cooling and waterproofing for high-power, fast-charging batteries. The pack has a sealed housing with a bracket inside forming multiple battery cell compartments. Fans are positioned to actively cool the cells through heat dissipation passages. This allows high-power discharges and quick recharges without overheating. The sealed compartments prevent water ingress. Temperature sensors monitor cell temps and fans/charging are controlled to maintain safe ranges.

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Battery pack thermal management to improve efficiency and extend life by utilizing waste heat from electronic devices and reducing temperature differences between battery compartments. The pack has separate cooling and heat recovery fans for the device and battery compartments. Sensors monitor temperatures at multiple positions. When the device compartment reaches a threshold, the fans are used to cool it. When the battery compartment is below a threshold, the fans transfer heat from the device compartment to heat the battery. This uses device waste heat to heat the battery in cold environments and balances temperatures.

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Energy-saving and heat-dissipating battery pack that reduces waste heat and improves cooling efficiency compared to conventional passive cooling methods. The pack has a shell with battery cells inside. Thermoelectric power generating sheets are attached to the side walls of the cells. A power converter and fan are also inside the pack. The thermoelectric sheets, converter, and fan are electrically connected. When the cells discharge, the converter converts excess power to drive the fan. The fan increases airflow around the cells to cool them. The thermoelectric sheets convert some of the waste heat into electrical power. This active cooling and waste heat recovery improves overall pack efficiency compared to passive cooling.

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