Air-Cooled Thermal Management for EV Battery Packs

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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