Heat Pipe and Vapor Chamber Design for EV Battery Cooling
41 patents in this list
Updated:
Electric vehicle battery packs generate substantial heat during operation, with cell temperatures routinely reaching 40-45°C during rapid charging and high-power discharge cycles. Traditional liquid cooling systems, while effective, add complexity and weight—typically 15-20% of the total pack mass—which directly impacts vehicle range and performance.
The fundamental challenge lies in achieving uniform temperature distribution across densely packed cells while maintaining a lightweight, passive cooling architecture that can handle both steady-state and transient thermal loads.
This page brings together solutions from recent research—including T-shaped vapor chambers for targeted heat extraction, U-shaped heat pipe networks for multi-cell cooling, and flat heat pipe arrays with integrated storage tanks. These and other approaches demonstrate how phase-change cooling systems can deliver efficient thermal management while reducing system complexity and weight.
1. Battery Module Incorporating Vapor Chambers with Phase-Change Heat Transfer Mechanism
HYUNDAI MOBIS CO LTD, 2024
Battery module with integrated vapor chambers for efficient cooling of the battery cells. The battery module has multiple vapor chambers filled with a working fluid placed between the battery cells. These chambers absorb heat from the cells, convert it to vapor, and transfer it to a heat transfer interface material. The interface material then channels the heat to an external cooling system. The vapor chambers circulate the working fluid between liquid and vapor states to efficiently cool the cells.
2. Battery Module System with Vapor Chambers and Thermal Grease Interface
GUANGDONG CHANGNENG INVEST HOLDING CO LTD, GUANGDONG CHANGNENG INVESTMENT HOLDING CO LTD, 2024
Power battery module system with improved thermal management using high thermal conductivity vapor chambers. The system has a housing enclosing multiple battery cells. Vapor chambers are sandwiched between adjacent cell surfaces and the housing. The vapor chambers have lower thermal resistance compared to conventional methods. Thermal grease is used between the chambers and housing contact points. This provides uniform and efficient heat transfer between cells and reduces temperature differences inside cells.
3. Battery with Passive Cooling Loops Incorporating Heat Pipes and U-Shaped Ducts for Homogeneous Thermal Management
AUTOMOTIVE CELLS COMPANY SE, 2024
Battery for electric vehicles that prevents hot spots and provides homogenous cooling without active cooling systems. The battery has passive cooling loops between the cell stack and casing. Each cell has a loop heat pipe, oscillating heat pipe, or heat pipe. The loops have evaporators in the cell stack and condensers in the casing. The loops circulate phase change fluid between the stack and casing to extract heat. The loops have U-shaped ducts in the stack and casing sections to connect evaporator and condenser. This provides thermal contact and circulation between stack and casing to distribute heat.
4. Battery Pack Thermal Management System with Planar Heat Pipes and Variable Performance Heat Sinks
TOYOTA JIDOSHA KABUSHIKI KAISHA, 2024
A thermal management system for battery packs in electric vehicles that provides uniform cooling and improves battery performance. The system uses planar heat pipes in direct contact with the battery packs to draw heat out, and heat sinks on the edges of the heat pipes to dissipate the heat. The heat pipes have opposed contact regions on the battery packs to balance heat distribution. The heat sinks have varying cooling performance to further optimize cooling.
5. T-Shaped Vapor Chamber for Battery Cooling with Bottom Heat Transfer and Top Heat Radiation Sections
GUANGDONG CHANGNENGDA TECH DEVELOPMENT CO LTD, GUANGDONG CHANGNENGDA TECHNOLOGY DEVELOPMENT CO LTD, 2024
Battery cooling structure using a T-shaped vapor chamber to improve cooling performance of batteries in high power applications where traditional flat plate vapor chambers can overheat. The T-shaped chamber has a bottom section that connects to the battery and transfers heat from the bottom of the battery. This prevents hot spots and allows even cooling. The top section radiates the heat to the surrounding environment. The T-shape allows the bottom section to soak up heat from the battery while the top section radiates it away, improving overall cooling compared to just a flat plate chamber.
6. Battery Module with Internal Heat Pipe Network Featuring Vacuumized Sealed Tube and Intercellular Heat Absorption Sections
STL TECHNOLOGY CO LTD, 2023
Battery module with improved heat dissipation using an internal heat pipe network to effectively cool the battery cells. The heat pipe structure has a vacuumized sealed tube above the battery holder to transfer heat by evaporating and condensing fluid. It also has a section inserted between adjacent cells to absorb cell heat. Connections between the sections allow heat transfer. This allows peripheral cell heat to be extracted and radiated by the top section.
7. Battery Module Heat Dissipation Device with U-Shaped Vapor Chamber and Integrated Condensing Plate
GUANGDONG CHANGNENGDA TECH DEVELOPMENT CO LTD, GUANGDONG CHANGNENGDA TECHNOLOGY DEVELOPMENT CO LTD, 2023
A battery module heat dissipation device for power batteries in electric vehicles that uses a U-shaped vapor chamber to quickly and evenly dissipate heat from the batteries. The device consists of a U-shaped heat absorber plate attached to the battery, and a condensing plate connected to a liquid cooling system. The absorber plate has evaporation ends on the battery sides and a condensation end at the bottom. The evaporation ends absorb battery heat, vaporizing a working fluid inside the U-shape. The vapor condenses on the cooling plate, transferring the heat to the liquid. This provides fast and uniform battery cooling to prevent overheating and thermal runaway.
8. Battery Module with Integrated Heat Pipe Evaporator Housing for Enhanced Thermal Management
CONTITECH TECHNO CHEMIE GMBH, CONTITECH TECHNO-CHEMIE GMBH, 2023
Battery module for electric vehicles that improves heat dissipation without adding complexity or cost. The module has a battery cell and a heat pipe with an evaporator and condenser. The evaporator is thermally coupled to the battery cell but electrically isolated. Uniquely, the evaporator forms a housing around the battery cell to enhance heat transfer. This improves cooling compared to just attaching the evaporator to the cell surface.
9. Flat Heat Pipe Configuration for Battery Module Thermal Regulation
TSINGHUA UNIV, TSINGHUA UNIVERSITY, 2023
Flat heat pipe cooling system for electric vehicle batteries that provides better thermal management compared to traditional liquid or air cooling. The system uses flat heat pipes to transfer heat between battery modules and a central cooling unit. The pipes are sandwiched between the modules or attached to one side of a module. This allows efficient heat transfer between modules and prevents hotspots. The central cooling unit has fins, fans, and heat exchange media to dissipate heat. It provides uniform temperatures across modules and prevents thermal runaway propagation. The flat heat pipe system is compact, simple, and convenient to assemble compared to liquid or air cooling systems.
10. Flat Heat Pipe with Integrated Liquid Storage Tank and Pressure-Driven Vapor-Liquid Circulation System
Sichuan New Energy Vehicle Innovation Center Co., Ltd., SICHUAN NEW ENERGY VEHICLE INNOVATION CENTER CO LTD, 2023
A flat heat pipe for power battery cooling that improves heat dissipation efficiency compared to traditional heat pipes. The flat heat pipe has a housing with a cavity and a liquid storage tank at the bottom. When the housing contacts the battery pack, heat from the pack increases the pressure in the housing. This causes the liquid to flow from the tank towards the pack side of the housing, absorbing heat as it vaporizes. The vapor then condenses back into liquid on the other side of the housing and flows back to the tank. This continuous loop transfers heat from the battery pack to the housing walls and back into the liquid, increasing overall heat dissipation efficiency.
11. Heat Dissipation Assembly with Vacuum-Sealed Vapor Cycle and Finned Chambers for Battery Packs
CHENGDU WOFEI TIANYU TECH CO LTD, CHENGDU WOFEI TIANYU TECHNOLOGY CO LTD, ZHEJIANG GEELY HOLDING GROUP CO LTD, 2023
Heat dissipation assembly for battery packs in electric vertical takeoff and landing (eVTOL) aircraft to improve cooling efficiency and reduce weight compared to liquid cooling. The assembly uses vacuum-sealed chambers filled with coolant that vaporizes at low temperatures. Soaking plates between battery cells contact their surfaces to increase heat transfer area. The vacuum chambers have fins for additional heat transfer. The coolant vaporizes in the chambers, enters the vacuum of the other chamber, condenses, and returns. This cycle extracts heat from the batteries without complex liquid systems.
12. Battery Pack Thermal Management System with Phase Change Vapor Chamber and Customized Wicking Material Distribution
ROMEO SYSTEMS INC, 2022
Thermal management system for battery packs that provides better temperature control compared to conventional methods. The system uses a vapor chamber filled with a working fluid that undergoes phase changes to absorb or release heat from the battery cells. The cells are positioned inside the chamber with wicking material between them and the fluid. This allows the fluid to carry heat away from the cells during charging/discharging. The chamber can be connected to a heat pump for active cooling. The wicking material quantity is customized for cells at different locations to optimize cooling.
13. Battery Module with Heat Pipe Structure for Enhanced Thermal Management
STL TECH CO LTD, STL TECHNOLOGY CO LTD, 2022
Battery module with improved heat dissipation using a heat pipe structure. The module has a shell, battery fixation frame, battery cores, and an improved heat pipe. The pipe has sections for absorbing core heat, conducting it upward, and condensing/evaporating fluid to transfer heat. This allows the core heat to be taken away and radiated. The pipe is above the core section and connects there.
14. Battery Module Cooling System with Direct Heat Pipe Integration
CHONGQING CHANG AN NEW ENERGY AUTOMOBILE TECH CO LTD, CHONGQING CHANG AN NEW ENERGY AUTOMOBILE TECHNOLOGY CO LTD, 2022
Automobile battery cooling system and vehicle that prevents battery overheating and thermal runaway. The cooling system involves inserting a heat pipe directly into the battery module and attaching it to the battery core. This allows rapid heat transfer between the core and the heat pipe, preventing hot spots and uniformizing core temperatures. The heat pipe can then be cooled externally to prevent overall module overheating. The direct core contact and heat pipe uniformization prevent piling up of heat in the battery core and reduce the risk of thermal runaway.
15. Battery Pack Thermal Management Structure with Heat Pipe and Heat Conduction Interface
TIANNENG NEW ENERGY CO LTD, TIANNENG NEW ENERGY HUZHOU CO LTD, 2022
A thermal management structure for battery packs that improves cooling efficiency and reduces temperature variability. The structure uses a heat pipe attached to the battery module. The heat pipe has an evaporation section, condensation section, and adiabatic section in between. The evaporation section absorbs heat from the module, and the condensation section releases it to the surroundings. The adiabatic section prevents condensation. The heat pipe connects to a heat conduction structure like glue or fins on the pack housing. This allows the condensation segment to transfer heat to the housing for dissipation, improving overall cooling.
16. Battery Module Heat Management System with Side and Bottom Contact Heat Pipes
GAC EON NEW ENERGY AUTOMOBILE CO LTD, 2022
Heat management system for battery modules in electric vehicles that reduces energy consumption and improves safety. The system uses a heat pipe with contact surfaces on the sides and bottom of the battery cell. This allows heat generated during charging and discharging to be transferred to the pipes and then to a liquid cooling plate below. This prevents heat buildup inside the cell and reduces the temperature difference across the module. The pipes also prevent hotspots near the electrodes.
17. Battery Pack with Integrated Liquid Cooling Plate and Heat Pipe Configuration
TIANNENG NEW ENERGY CO LTD, TIANNENG NEW ENERGY HUZHOU CO LTD, 2022
Integrated liquid cooling and heat pipe design for battery packs to improve cooling efficiency and temperature uniformity. The design involves fixing a liquid cooling plate on the top of the battery module and a heat pipe on the side and top surface. The heat pipe contains coolant and transfers heat from the side of the module to the cooled plate. This direct connection eliminates air gaps and reduces thermal resistance compared to separate liquid and plate components. It allows better heat extraction from the battery cells and more uniform cooling.
18. Battery Cooling System with Integrated Heat Pipes and Offset Vapor Channels
DR ING H.C F PORSCHE AKTIENGESELLSCHAFT, PORSCHE AG, 2022
Battery cooling system for electric vehicles that improves efficiency and reduces space requirements compared to conventional cooling methods. The cooling system uses heat pipes with an internal working fluid to transport heat away from the battery cells. The cells are positioned inside the heat pipes so they directly contact the internal condensate channels. This allows direct heat transfer between adjacent cells through the condensate channels. The vapor channels are offset to alternate between cells. This enables efficient heat transfer between cells while minimizing the number of external connections needed compared to connecting the heat pipes directly to each cell.
19. Battery Pack with Integrated Heat Pipe and External Cooling Unit for Thermal Management
HA JEONG SEOK, 2022
Battery cooling device for electric vehicles that cools the battery when it gets too hot during charging and discharging. It uses a heat pipe inside the battery pack to transfer heat from one side to the other. A separate cooling unit cools part of the heat pipe to further reduce battery temperature. This improves battery efficiency and lifespan by preventing overheating.
20. Dual-Stage Heat Pipe Battery Cooling System with Integrated Thermal Management
HA JEONG SEOK, 2022
Battery cooling system for electric vehicles that efficiently cools batteries during charging and discharging to improve performance and lifespan. The system uses a heat pipe inside the battery pack to transfer heat from the cell to an external cooling unit. Another heat pipe cooling unit inside the pack further cools the heat pipe. This dual-stage cooling is more effective than just an external unit. The system also allows applying heat when ambient temps are lower than optimal charging/discharging temps to compensate.
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