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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Power battery thermal management system for electric vehicles that improves cooling and temperature uniformity compared to conventional designs. The system uses a fan, radiator, and heat conductor between cells to rapidly dissipate heat from the battery pack. The fan accelerates airflow around the cells to transfer heat to the radiator on the opposite side. The heat conductor between cells accelerates heat transfer between them. This faster cooling and uniformization is especially important for lithium batteries that are sensitive to temperature extremes.

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An air-cooled battery pack design for small-scale air-cooled energy storage systems. The battery pack has a box with an internal cooling chamber that the battery module is inserted into. Air channels are formed at the top and bottom of the module to connect to the chamber. Gaps on the sides of the box allow external air to flow into the channels. This provides forced air cooling of the battery module through the chamber. The pack can be used in air-cooled energy storage systems without modifying the container.

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Phase change composite battery thermal management system that integrates cooling, heating, and waste heat recovery to efficiently maintain optimal battery operating temperature. The system uses a phase changer, heat exchanger, electric heater, thermoelectric converter, and valve. Air is circulated through the system to cool the battery during normal operation. In low temperatures, waste heat from thermoelectric conversion is used to heat the battery. This prevents battery degradation and thermal runaway by maintaining optimal temperature.

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Cooling system and method for battery thermal management that prevents dust accumulation inside the battery while still effectively cooling the battery. The system uses a rotating fan embedded in the bottom of the battery box that automatically turns to face the heat exchange fins. This prevents dust from blowing into the box and settling on the fins. The fan is actuated by a push component that translates when condensate enters a channel. Additionally, the system has a liquid cooling loop with a pump, heat exchanger, and storage tank to cool the battery. A ventilation assembly cools the return pipe with wind. The system relieves pressure and provides full cooling for the return pipe.

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A chassis-integrated high-voltage (HV) battery thermal management system for electric vehicles that reduces space requirements and complexity compared to liquid-cooled battery packs. The system integrates the battery chamber and cooling plate into the vehicle chassis. Heat pipes transfer heat from the battery cells to the chassis. Cooling fins on the chassis surface sink the heat into the ambient. This eliminates separate cooling tubes and tanks while utilizing the vehicle structure for heat dissipation.

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Thermal management system for electric vehicle battery packs that uses both air and liquid cooling to improve temperature consistency and prevent damage. The system has a battery box with a phase change material, a cooling module with air ducts and a fan, and a speed regulating fan. The phase change material absorbs heat during charging and releases it during discharging. Air is circulated by the fan through the cooling module and ducts to dissipate heat. The system also uses a thermocouple to monitor temperature. The combination of air and liquid cooling provides better temperature control and consistency compared to just air or liquid cooling alone.

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Air-cooled and liquid-cooled hybrid heat dissipation system for lithium-ion batteries that provides more consistent and efficient cooling compared to just air or liquid cooling. The system uses temperature sensors in the battery pack to detect hot spots. If any battery gets too hot, it sends an air cooling instruction to the main air cooler. If still too hot, it also sends a liquid cooling instruction to the internal liquid coolers. This combined air and liquid cooling provides targeted cooling to hot areas while preventing overcooling of cooler areas. The air and liquid coolers have adjustable settings based on the detected battery temperatures.

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Battery pack thermal management system that enables precise temperature control of individual cells in a battery pack. The system uses separate detection devices for each cell to monitor internal parameters like temperature, voltage, current. A control device connects to the cell detection and the heat exchanger. It uses the cell data to selectively cool or heat cells through the exchanger. This allows regulating cell temperatures independently instead of whole pack regulation.

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Efficient cooling system for battery packs in electric vehicles that prevents temperature imbalance between cells. The system uses a sealed cylinder with multiple battery modules separated by cooling plates. Heat pipes connect adjacent modules. Inside the cylinder, guide fans disturb air flow. Outside, cooling fans dissipate heat. Temperature sensors monitor pack and pipes. A control unit coordinates fan speeds based on readings. This balanced cooling prevents hotspots and extends battery life.

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A lithium-ion battery pack cooling system with real-time temperature monitoring to prevent overheating and improve safety. The cooling system uses a wind speed sensor inside the cooling tank to measure the actual airflow velocity. This allows calculating the actual heat dissipation efficiency of the cooling module. If a battery cell overheats, the blower power is increased to provide directed cooling airflow. If that fails, the controller reduces the battery discharge rate to lower the pack temperature. The real-time temperature monitoring enables proactive cooling measures before thermal runaway.

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Electric vehicle battery thermal management system to balance heat dissipation across multiple battery packs in a pack arrangement. The system uses partition boxes between adjacent battery packs made of heat-conductive copper alloy with insulation seals. The partition boxes have cavities and end tubes with seals. This allows controlled heat transfer between packs. Temperature sensors in the partition boxes monitor pack heat levels. Valves direct airflow through the boxes to circulate hotter air to cooler packs. This prevents high-temperature packs from heating adjacent packs excessively.

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Battery pack with an improved thermal management system that provides effective cooling and temperature uniformity without adding complexity or parasitic power consumption. The pack has a baffle structure between adjacent battery modules that guides a controlled flow of air through serpentine pathways. This recirculates air between modules for uniform cooling. The baffle structures attach to the connecting members between cells. The pack also has channels, blowers, and fins for recirculating and dissipating the air.

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Smart and dynamic cooling system for vehicle batteries that cools each cell individually and maintains a desired temperature range. The system has a movable cooling fan mounted on sliding channels. It moves over the battery pack to provide targeted cooling to hotter cells. Thermal sensors detect hot spots and guide the fan there. This dynamic cooling prevents uneven temperatures that degrade performance. The fan sweeps over the pack to distribute heat evenly.

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Thermal management system for electric vehicle batteries that uses a refrigerant-based cooling loop and an air duct to cool the batteries without using liquid coolant. The system has a refrigeration path with a compressor, heat exchangers, and throttle, and a battery cooling path with a fan, duct, and battery pack. In refrigeration mode, the refrigerant circulates and cools the battery pack. In natural cooling mode, the fan circulates air through the duct and cools the pack. This eliminates liquid leakage risks compared to liquid cooling.

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Compact heat dissipation device for energy storage power supplies like battery packs and inverters to improve cooling efficiency and allow higher power density. The device separates and cools both components independently using a heat sink, air duct, and air cooling fin. The battery pack and inverter are mounted on opposite sides of the duct, with the fin in the gap between them. Air flows through the duct to cool the inverter, while heat from the battery pack is guided to the fin and duct to be dissipated. This allows simultaneous cooling of both components in a compact layout.

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Thermal management system for power batteries in electric vehicles that improves heating and cooling efficiency, especially in cold weather. The system uses a looped power supply between the battery pack and a supercapacitor to quickly heat the battery when starting in cold conditions. It also has a liquid cooling channel and heat conduction pipes inside the battery case to efficiently dissipate heat. The system monitors battery temperature with a sensor and controls the heating and cooling units accordingly.

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Battery system design to prevent thermal events from spreading between battery packs. The system has a duct connecting the packs and a fan to circulate air. Filters at the pack connections prevent oxygen ingress. During thermal events, vented gases are directed through the duct and fan instead of spreading to adjacent packs. This isolates and confines the issue to the affected pack.

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An energy storage battery module with integrated thermal management and a method to cool the battery module. The module has fans at the top and sides to circulate air around the battery pack. This improves heat dissipation compared to just relying on natural convection. The top fan has a high speed to generate cyclones that circulate air around the pack. The side fans blow air on the sides. The module also has a water cooling system with a pump, tank, and rotating cylinder to crush and stir ice cubes. This rapidly cools the battery pack in hot environments. The fans and water cooling complement each other for efficient cooling.

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Battery cooling system for electric vehicles that improves temperature uniformity across the battery pack. It uses both water-cooling for the lower part and air-cooling for the upper part. The lower part has a water-cooled heat sink, while the upper part has an air-cooled blower. This hybrid cooling approach balances temperature in both sections to prevent temperature gradients that can degrade battery life.

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Air-cooled battery pack thermal management system for electric vehicles that simplifies the cooling setup while meeting heating and cooling demands. It uses a compact air-cooled battery pack enclosure with integrated heat exchangers for both heating and cooling. The pack is surrounded by a closed air circulation loop with a pump, fan, and temperature sensor. The pack exchangers exchange heat with the circulating air to regulate the pack temperature. This eliminates the need for separate heating and cooling systems. A control algorithm monitors pack temperature and optimizes loop flow rates for efficient cooling/heating.

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Energy storage system for cooling and heating battery packs using a single pump and two valves, instead of separate pumps and valves for each component. The system has a pump, radiator, battery pack, power converter, and two valves. The valves can send fluid to the battery pack, power converter, or radiator. A controller adjusts the flow rates based on temperatures. This allows optimized cooling where needed. The radiator also has a fan to quickly cool when needed. The valves are a rotating distribution pipe with one inlet and two outlets. A motor rotates the valve to change flow directions.

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Battery pack module with improved heat dissipation using dual-channel cooling. The module has a base plate with fixed plates on each side. Battery packs are installed between them. A middle air duct runs between the packs. An air inlet blows air into the duct. A diversion assembly slides air into the duct when the temperature tube expands. Liquid cooling channels are interspersed between packs. The diversion assembly diverts air from the duct into pack gaps. Fans, baffles, and guides manage the airflow. The dual-channel cooling combines liquid and air for efficient heat dissipation.

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Power battery pack assembly for electric vehicles that improves battery life, safety and thermal management. The assembly has a radiator integrated into the bottom of the battery pack. This allows heat dissipation, temperature balancing and absorption of internal impacts. The radiator has fins, airflow guides and a heat pipe to enhance cooling. It prevents thermal runaway, extends battery life, protects the bottom and absorbs internal strikes.

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Battery pack cooling system for electric vehicles that maximizes cooling efficiency even when a duct structure is used inside the battery pack housing. The system includes a duct extending from an intake port to an exhaust port, a heat pipe contacting the battery cells, and a heat sink inside the duct. This allows airflow through the duct to extract heat from the heat pipe and cells. The duct, heat pipe, and heat sink are arranged in the pack housing to isolate the cooling system from the internal battery space. This prevents contamination and allows natural air intake while driving.

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Air-cooled power battery thermal management system for electric vehicles that uses phase change materials and semiconductor cooling to effectively cool the batteries without issues like leaks or high cost of liquid cooling. The system combines phase change materials to absorb heat from the batteries, semiconductor cooling to provide additional cooling, and air flow to distribute the cooling. It uses phase change microcapsules between the battery cells to absorb heat, semiconductor cooling sheets connected to the battery pack shell for direct cooling, and a blower fan to circulate air through the battery pack. This provides uniform cooling without hot spots. The cooling is controlled based on battery temperature sensors.

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Electric vehicle battery pack cooling system with simple and efficient control to optimize cooling while minimizing energy consumption. The system uses adjustable speed pumps and fans along with sensors to dynamically adjust cooling based on battery temperature. It involves closely attaching a liquid cooling plate to the battery pack, using an adjustable speed pump to circulate coolant through the plate, a radiator, and fan to dissipate heat to the air. The system has sensors on the battery pack surface to monitor temperatures. A controller adjusts pump and fan speeds based on sensor readings to achieve cooling without overspending on power.

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An air-cooled battery pack for vehicles that provides efficient cooling while preventing overcooling when outdoor temperatures are low. The battery pack has an enclosure with inner fins to transfer heat from the batteries to air circulated by a blower. It also has external fins that release heat to outside air. The blower shuts off when battery temperatures drop below a threshold to prevent overcooling. This allows cooling using both enclosure airflow and outside air.

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A battery pack with heat dissipation fan to prevent overheating and improve cooling of multi-cell battery packs. The pack consists of multiple battery bodies connected together, surrounded by a housing with a fan, ventilation, and heat dissipation features. The fan is connected to the batteries and draws air through the housing to cool them. The housing has ventilation holes and a radiating column to dissipate heat to the outside. The fan, ventilation, and column prevent internal temperature buildup. The housing is fixed to prevent movement during operation.

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A battery cooling system that combines air cooling and liquid cooling to efficiently cool batteries in electric vehicles. The system uses a heat dissipating assembly wrapped around the battery cells that has both an S-shaped liquid cooling pipe and a bottom-mounted cooling fan. A temperature sensor on the battery side wall sends data to the battery management system (BMS) which controls the fan and water pump based on the cell temperatures. This allows adaptive air and liquid cooling to maintain optimal battery temperature within a narrow range.

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A battery pack design for electric vehicles and other applications that enables operation in cold temperatures without degradation. The battery pack has a thermally controllable housing with integrated heating and cooling elements. The housing surrounds the battery modules and can be adjusted to maintain optimal cell temperatures. In cold environments, the housing heats the modules using resistive foil heaters. In hot environments, the housing cools the modules using an integrated cooling system. This allows using battery chemistries that are less temperature sensitive, broadening the options for cold climate vehicles. The housing also contains temperature sensors to monitor cell conditions and a microcontroller to activate the heating/cooling as needed.

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