Ferrofluids for Electric Vehicle Battery Thermal Management

A cooling system for electric vehicles with high-voltage batteries that allows effective cooling without large oil cross-sections and additional sealing. The system uses a heat exchanger to transfer heat from the battery oil cooling circuit to a separate water-based cooling circuit. This allows the battery to be actively cooled exclusively with oil while the other vehicle components are cooled with water. The heat exchanger transfers heat between the two circuits instead of using larger oil lines to cool everything. It reduces oil volume, mass flows, and system size while still providing high cooling capacity for the battery.

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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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Lithium battery thermal management using different coolants to improve cooling efficiency. The method involves optimizing the concentration of nanoparticles in nanofluids used for battery cooling. The nanoparticles are added to the base fluid of water and ethylene glycol. Increasing the nanoparticle volume fraction initially improves cooling, but adding too many nanoparticles increases pump workload. The optimal nanoparticle concentration is found by testing. This provides a scientific and rational way to deploy metal particles in nanofluids to enhance cooling without excessive pump power.

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Heat transfer fluid for electrical apparatus that enhances thermal management through a novel ester-based formulation. The fluid comprises at least one ester of C5-C9 monocarboxylic acid and C5-C9 monoalcohol with a carbon number less than 17, combined with additives such as antioxidants, metal deactivators, friction modifiers, corrosion inhibitors, and anti-wear additives. The ester-based formulation offers superior dielectric properties, biodegradability, and improved thermal conductivity compared to conventional fluorinated and water-based fluids, enabling efficient heat transfer in applications requiring low-temperature operation.

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Battery pack for electric/hybrid vehicles with improved thermal management and reduced cost. The battery pack uses a plastic housing instead of metal to insulate the cells and has integrated fluid channels molded into the housing. This eliminates the need for separate cooling plates and hoses. The plastic housing is assembled with screws to allow disassembly for maintenance. The internal fluid channels distribute and collect cooling fluid directly within the housing. The plastic housing insulates the cells from external temperatures, simplifies manufacturing, and eliminates corrosion compared to metal housings. The vehicle can have multiple of these plastic battery packs.

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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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Heating device for vehicle thermal management systems that prevents thermal degradation of heating elements by controlling heat transfer through a novel heat management system. The device features a heat generation region with strategically positioned dissipating elements that distribute heat across the heating element surface, preventing thermal stratification and precipitation. The dissipating elements are integrated into the heating plate, with channels formed by the elements that facilitate heat transfer while minimizing pressure drop. The system achieves optimal heat transfer while maintaining the integrity of the heating element, enabling continuous operation in vehicles without the need for additional cooling systems.

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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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Electric vehicle power battery with enhanced thermal management through a novel expansion mechanism. The battery is connected to a support frame via elastic components that slide along telescopic mounting frames. The mounting frames are positioned on both sides of the frame, with the upper mounting frames connecting to the front and rear support frames. The lower mounting frames connect to the rear support frames. The expansion mechanism, driven by a dispersing mechanism, enables the mounting frames to move laterally while the batteries expand outward. This design enables the battery to move freely while maintaining structural integrity, while the dispersing mechanism ensures proper battery alignment. The system also includes a reversing mechanism with an electric push rod that enables the battery to rotate and reverse.

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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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Cooler for electric vehicle batteries that provides improved cooling performance and prevents degradation of tube strength during manufacturing. The cooler has a design where all components are mechanically fastened together in a fluid-tight manner instead of brazing. The tubes, collector, and cover are assembled without filler metal. Seals compress between the tube, collector, and cover instead of brazing. This prevents deformation, warping, and defects in the tubes caused by brazing. The mechanical assembly allows better cooling and strength retention compared to brazed coolers.

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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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Nanofluid with improved cooling efficiency for renewable energy systems like solar collectors. The nanofluid is made by dispersing core-shell nanoparticles in a base fluid. The core contains a magnetic material and the shell is carbon. The magnetic core allows controlling particle flow using a magnetic field. The carbon shell prevents agglomeration. The nanofluid has enhanced thermal conductivity compared to the base fluid due to the high thermal conductivity of the nanoparticles. This improves cooling efficiency in applications like solar collectors.

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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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