Ferrofluids for Electric Vehicle Battery Thermal Management

A temperature management system for batteries that enables efficient heat transfer between the battery cells and the surrounding environment. The system comprises a network of interconnected conduits that circulate cooling or heating fluids through the battery cells, with the conduits extending through the entire cell volume. The system incorporates vortex flow, spiral flow, and temperature-sensitive sensors to optimize heat transfer and minimize temperature gradients between cell layers. The system is particularly effective for large battery cells where conventional cooling methods are insufficient.

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Thermal management fluid for cooling high-temperature electrical components like batteries without using water-based coolants. The fluid is dielectric to enable direct contact cooling of electric components without electrical insulation requirements. It has a high flash point and low viscosity for efficient heat transfer. Compounds like 1,10-di-tert-butoxydecane and derivatives are used. The fluid absorbs heat from components like batteries and transfers it through the system. This provides cooling without the risk of ignition from oxygen ingress.

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A thermal management fluid for lithium-ion battery systems that enables direct cooling of components through electrical shielding. The fluid, comprising dielectric compounds with high dielectric constant and low viscosity, can be pumped through a system with electrical insulation to carry heat away from battery components. The fluid's high dielectric constant prevents electrical conduction while maintaining sufficient thermal conductivity for efficient heat transfer. This enables direct cooling of components without the need for conventional heat sinks or electrical shielding, while maintaining electrical insulation.

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Ultra-low conductivity thermal management fluid for lithium-ion battery packs that achieves efficient cooling while minimizing coolant volume. The fluid comprises a matrix of 42-48 parts of coolant, 5-10 parts of dipropylene glycol methyl ether, 22-26 parts of water, 5-8 parts of surfactant, 1-3 parts of corrosion inhibitor, 0.5-1.0 parts of 2,6-di-tert-butyl-p-cresol, and 10-20 parts of temperature-sensitive additives. The fluid maintains a low viscosity and surface tension at 40°C, with a controlled phase change temperature of 40-55°C. The fluid is designed to be injected into the battery pack through a single entry point on one side of the conductive row, with the pack height not exceeding 2/3 of the battery height.

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Thermal management fluid for lithium-ion batteries that prevents overheating and battery fires through a novel combination of thermal management and corrosion protection. The fluid comprises a specific blend of compounds that combine to prevent thermal runaway while maintaining high conductivity and preventing corrosion of metal components. The solution addresses the conventional thermal management challenges of lithium-ion batteries by controlling both heat dissipation and preventing thermal runaway, while also addressing the corrosion concerns associated with traditional thermal management fluids.

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Dielectric thermal management fluid for cooling electrical components like batteries without electrical insulation. The fluid has a low viscosity and high flash point to enable pumping and prevent ignition. It is suitable for direct cooling of electrical components like batteries. The fluid contains dielectric compounds with specific structures that balance thermal properties like heat capacity, conductivity, and expansion with low viscosity and flash point. This allows efficient heat transfer while preventing ignition.

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A power battery pack heat dissipation system that combines nanofluid-based pulsating heat pipes with advanced heat management features. The system integrates a nanofluid heat transfer fluid into the heat pipe design, enabling enhanced heat dissipation through both phase change and conduction mechanisms. The nanofluid is specifically selected for its high thermal conductivity, while the pulsating heat pipe configuration ensures efficient heat transfer between the battery core and heat pipe. The system features a compact battery pack design with integrated cooling fins and an external heat dissipation shield, providing rapid heat dissipation through both natural convection and forced convection.

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A lithium-ion battery thermal management fluid for electric vehicles that combines superior thermal conductivity and specific heat capacity with enhanced heat transfer efficiency. The fluid comprises a main liquid component and an auxiliary liquid component, with a specific ratio of 100:14. The main liquid component is a high-performance coolant with enhanced thermal conductivity, while the auxiliary liquid component is a quantum dot-enhanced coolant that significantly improves heat transfer efficiency. The fluid is formulated to maintain optimal temperature control within the battery pack while achieving the required thermal management performance.

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A battery pack that eliminates the need for external cooling systems while maintaining precise temperature control through a novel magnetic field-based system. The battery pack integrates a temperature monitoring module with a magnetic field generator that produces controlled magnetic fields. These fields interact with the battery's internal magnetic field to regulate heat transfer through the battery management system. This integrated magnetic field control enables precise temperature monitoring and feedback without the environmental and safety concerns associated with traditional cooling systems.

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Heat transfer system and method for cooling electrical components in power electronics, particularly in battery management systems, using a stable colloidal dispersion of a non-conductive, non-aqueous, and water-immiscible dielectric fluid. The dispersion comprises a dielectric fluid, at least one solid nanoparticle, and a surfactant. The dielectric fluid contains a Group V base oil, and the surfactant is an anionic surfactant. The dispersion maintains low electrical conductivity, low flammability, and low freezing point, making it suitable for cooling electrical components in power electronics applications.

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Electric vehicle battery cooling system using nanofluid with enhanced heat transfer capability. The system has three loops: a cold start loop, a regular heat dissipation loop, and an enhanced heat dissipation loop. The nanofluid, like ethanol with silicon carbide nanoparticles, is pumped through the loops. The enhanced loop has internal and external circulation paths with a deionizer to reduce conductivity. The external path has cosine-curved microchannels. This system improves battery cooling in high power applications by using the nanofluid for better heat transfer and the enhanced loop for extra dissipation.

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A dielectric thermal management fluid for lithium-ion battery cooling that combines high thermal conductivity with low viscosity. The fluid contains a dielectric component with a flash point greater than 120°C and a halocarbon component with boiling points between 60°C and 200°C. The fluid maintains a dielectric constant of at least 1.5 at 25°C while achieving a low viscosity suitable for direct cooling applications. This composition enables efficient heat transfer while minimizing ignition risks, particularly in battery systems where electrical components are exposed to high temperatures.

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Heat transfer fluid for battery and other electrical equipment systems that combines excellent thermal conductivity and tribological performance. The fluid comprises a nanoparticle-encapsulated polymer matrix, where the nanoparticle components are single-walled carbon nanotubes and the polymer matrix is formed from a polymerization reaction of monomers such as aminoalkyl and aminoalkyl methacrylates.

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Inorganic-polymeric nanoparticle-based heat transfer fluid for battery and other electrical equipment systems that improves thermal management through stable dispersion of nanoparticles in hydrophobic media. The composition comprises inorganic nanoparticles and polymer components, with the polymer components being obtained through polymerization of specific monomers. The resulting dispersion maintains nanoparticle integrity over extended thermal cycles, enabling enhanced heat transfer and thermal conductivity in applications such as electric vehicles, electric motors, and power electronics.

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Thermal management system for lithium-ion batteries that enables both direct and indirect cooling through a single fluid circuit. The system comprises a heat source, a first heat exchanger, and a first fluid circuit that circulates a thermal management fluid between the heat source and the first portion of the first heat exchanger. The first fluid circuit is configured such that the first thermal management fluid can absorb heat from the heat source and can dissipate heat in the first heat exchanger. The system also includes a second fluid circuit configured to pass a second thermal management fluid over the second portion of the first heat exchanger and absorb heat therefrom. The first thermal management fluid includes dielectric fluids present in a range of 65-99.9 wt % and halocarbons with boiling points between 30-150°C, with a dielectric constant of at least 1.5 at 25°C, and a flash point above the boiling point of the halocarbons.

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Heat dissipation fluid composition for battery cooling that prevents settling of particles to maintain performance over time. The composition is a two-phase mixture of immiscible liquids, a non-conductive oil and a first liquid, along with hollow inorganic particles. The particles contain a second liquid miscible with the first liquid. This prevents particle settling by dispersing them in the upper oil layer. The composition provides high thermal conductivity and prevents settling of particles in battery modules to improve cooling.

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Adaptive battery cooling control for electric vehicles that dynamically adjusts cooling modes based on real-time temperature and current state conditions. The control system monitors temperature and current output to determine the optimal cooling cycle mode, enabling precise temperature management that balances performance and safety. This adaptive approach enables the system to quickly respond to temperature changes while maintaining optimal battery health and performance.

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A heat transfer fluid for electric vehicle power systems that enables peak temperature reduction through controlled heat dissipation from electrical components. The fluid combines water, a C2-C12 metal carboxylate, and a soap, achieving low electrical conductivity, low flammability, and low freeze point properties. This fluid enables efficient heat transfer in power electronics while maintaining electrical safety. The fluid is circulated through a heat transfer system that interfaces with electrical components, allowing precise control over heat dissipation. The fluid's unique properties enable effective temperature reduction without compromising electrical safety or system performance.

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A thermal management system for battery modules that prevents thermal runaway diffusion between adjacent cells. The system comprises a battery module with a package containing multiple battery cells, a cavity within the package, and a gas-absorbing agent positioned within the cavity. The gas-absorbing agent absorbs heat generated by thermal runaway reactions between adjacent cells, preventing the thermal runaway diffusion that can lead to cell failure and safety hazards.

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Battery pack system with a rapid thermal management system that enables immediate intervention in overheating battery cells. The system comprises a battery pack module with sealed battery cell containers, a cooling system delivering coolant directly to the affected cell, and a valve-controlled system that rapidly responds to overheating conditions. The valve enables controlled delivery of cooling fluid to the affected cell, preventing thermal runaway and enabling quick intervention before damage occurs.

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An intelligent temperature control system for electric vehicle batteries that provides precise temperature regulation for optimal battery performance and longevity. The system uses a controller, sensors, pumps, valves, coolers, and heaters to maintain battery temperature within optimal ranges. It has separate circuits for heating, cooling, and balancing temperature distribution. The controller adjusts these circuits based on cell temperature readings. It also coordinates with other components like the passenger compartment cooling system to ensure overall vehicle temperature balance. This comprehensive temperature management improves battery health and vehicle range compared to basic heating/cooling.

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Coolant for electric vehicle batteries that maintains temperature stability through phase change material encapsulation. The coolant contains a phase change material encapsulated in a microencapsulated matrix, surfactant, and a solvent. The surfactant is sorbitan sesquioleate, and the phase change material is a mixture of paraffin, inorganic salts, salt hydrates, carboxylic acids, and sugar alcohols. The coolant's composition is optimized to achieve a 9:26 surfactant to phase change material mass ratio, with a thermal conductivity improving additive added for enhanced heat transfer.

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Battery pack design to improve cell consistency and prevent thermal runaway propagation. The pack uses a temperature-controlled housing for each cell. The housing conducts heat when the cell temperature is between two reference values, but blocks heat exchange outside those ranges. This maintains cell temperature uniformity. If a cell overheats, the housing blocks heat spread to prevent chain reaction. A heating element warms below threshold. The pack also has enclosures with heat barriers between cells.

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Passive protection battery module for electric vehicles that prevents thermal runaway and explosion through optimized cell-to-cell thermal management. The module comprises a battery cell array with fire-resistant spacers that separate cells in pairs, each containing a mica sheet and fire-resistant coating. The spacers are heated by the mica sheet, creating a thermal barrier that prevents adjacent cells from overheating. This dual-layered approach ensures that each cell is protected from thermal stress while maintaining optimal cell-to-cell thermal management. The module's design enables rapid thermal response times for individual cells, preventing prolonged thermal runaway events that could compromise vehicle safety.

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An assembly element for battery cooling and thermal runaway prevention that combines a thermally conductive block-barrier assembly with a structural design. The assembly comprises a cylindrical hole formed through the structural design, which enables rapid heat dissipation through air, liquid, phase change material, or heat pipe cooling paths. This design enables efficient heat transfer while preventing thermal runaway by creating a controlled thermal pathway. The structural design integrates the thermal barrier with the cooling mechanism, addressing the traditional thermal runaway issue by simultaneously enhancing cooling performance and preventing thermal runaway.

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Battery module with dual thermal management capabilities that prevents thermal runaway by controlling heat transfer and absorption. The module features a composite heat management system comprising a thermally conductive sheet, a heat-absorbing layer, and a protective layer. The thermally conductive sheet facilitates heat transfer between cells, while the heat-absorbing layer absorbs and dissipates heat. The protective layer prevents cell damage during thermal stress events. This innovative design addresses the thermal management challenges associated with battery packs while maintaining structural integrity.

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Micro heat exchangers for managing vehicle battery temperature through nanofluid-based heat transfer. The system integrates custom-designed micro heat exchangers into battery components, utilizing microfluids with engineered particle sizes to optimize heat transfer properties. These micro heat exchangers enable precise temperature control through both heating and cooling applications, providing a compact and efficient solution for battery management systems.

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A thermal management system for electric vehicles that combines phase change materials with a thermal shell to improve battery cooling and prevent thermal runaway propagation. The system features a phase change material (PCM) encapsulated within a thermal shell, which enhances heat transfer while maintaining temperature uniformity. The PCM acts as a thermal barrier between the battery cells, preventing thermal runaway while maintaining efficient cooling. This dual-layer design addresses the traditional cooling challenges of battery systems by addressing both cooling capacity and thermal stability.

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Electric vehicle battery pack charging and heating system that optimizes battery temperature management through advanced thermal management. The system employs a sophisticated temperature monitoring and control architecture that dynamically adjusts charging and heating parameters to maintain optimal battery operating temperatures. This enables real-time temperature control, precise charging power, and enhanced energy efficiency, particularly in cold weather conditions. The system integrates with the vehicle's battery management system to optimize charging and heating strategies for each battery pack, ensuring consistent battery performance and reducing charging time.

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A battery cooling system that enables efficient cooling of lithium-ion batteries while minimizing weight and maintaining thermal stability. The system integrates a compact, heat-sink-based cooling module into the battery cell housing, with a unique gas flow configuration that maintains uniform temperature distribution throughout the battery pack. This innovative approach enables precise temperature control while maintaining the battery's safety and performance characteristics.

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Thermal management system for high-voltage batteries in electric vehicles that utilizes advanced cell-to-cell heat dissipation through strategically positioned thermal interfaces. The system employs a novel approach where thermal interfaces are integrated into the battery cell design, with specific cell separators positioned to facilitate heat transfer between adjacent cells. This configuration enables efficient heat dissipation across the battery array while maintaining structural integrity.

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A method for controlling battery temperature in electric vehicles that eliminates the need for frequent switching between heating and cooling modes. The method involves a single control mechanism that monitors and regulates both temperature control modes simultaneously, using a single pump and valve system. The system maintains optimal battery temperature through continuous liquid circulation, with automatic switching between heating and cooling modes based on temperature thresholds. This approach eliminates the need for separate heating and cooling systems, reducing complexity and maintenance requirements.

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