Heat Sinks for EV Battery Cooling

Battery module design that simplifies cooling structure, improves cooling performance and increases space utilization compared to conventional battery modules. The module has a battery cell stack, housing, and integrated heat sink at the bottom. The heat sink has an upper plate that is also the housing bottom, with a refrigerant flow path between the plates made of different metals. This simplified integrated heat sink reduces thermal resistance and air gaps compared to separate housing, heat transfer member, and heat sink components. The refrigerant circulates between the plates to extract heat from the cells and dissipate it to the exterior.

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Battery module with improved cooling performance for high capacity battery packs. The module has a simplified cooling structure by integrating the module frame and a heat sink. This reduces the number of thermal interfaces and air gaps compared to separate components. The integrated heat sink forms a cooling flow passage between the upper plate and upper cover of the frame. The module also uses a thermally conductive resin layer between the cells and lower frame part for additional cooling. This simplified, integrated cooling path improves heat transfer and reduces thermal resistance compared to separate components.

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Battery assembly for electric vehicles that provides improved thermal management of pouch cells to prevent overheating and degradation. The assembly uses cooling plates with contact areas to thermally bond to the flexible pouch cell surfaces. This allows expansion/contraction while maintaining thermal contact. Securement bars hold the plates to a heat exchange panel. This enables the cells to move without breaking the thermal connection, preventing cell swelling/popping issues. The plates also have exchange areas to contact the heat exchanger.

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Battery pack design for electric vehicles with improved thermal management and safety. The pack uses a double-layer configuration with two battery modules stacked together. Cooling plates are attached to the top of each module. This allows effective liquid cooling of both modules during operation. The pack also has relief cavities connected to explosion valves and pressure relief channels to prevent gas leakage if cells overheat. The relief cavities isolate pressure buildup to avoid affecting other components.

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Fractal heat sink design that increases heat dissipation compared to conventional heat sinks. The fractal geometry of the heat sink surface provides a chaotically distributed surface area that disrupts the stagnant boundary layer of fluid flow. This chaotic surface increases the effective surface area available for heat transfer, while avoiding acoustic resonance. The fractal geometry also allows for variation in flow rate and direction over different scales. The fractal heat sink design improves heat dissipation efficiency by increasing the surface area available for convective and radiative heat transfer.

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Battery module with improved cooling and structural stability for large-area modules used in high-power applications like electric vehicles. The module has a heat sink integrated below the housing. Cooling ports connect the heat sink to the housing. The end plate has protrusions that match the lead protrusions from the cells. This allows direct cooling of the cells without vulnerable connections. The integrated design provides better cooling and prevents deformation.

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Heat dissipation module for power conversion devices like battery packs that improves cooling efficiency by preventing heat buildup inside the enclosure. The module has a heat transfer path between the power electronics and a separate heat sink. This path has multiple sub-paths that connect the electronics and heat sink, with spaced apart paths between them. This allows better convection cooling by breaking up the heat source into smaller regions rather than having a solid block of heat between the components and heat sink. The heat sink also has holes aligned with the sub-paths to further enhance convection.

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Electric vehicles (EV) are advancing rapidly, with increasing demand for enhanced technological support. One of the key challenges EVs is ensuring adequate power storage, a critical parameter being battery pack's ability to support high discharge rate. Achieving rate requires proper cell design and efficient heat management within pack. During discharge, generation becomes significant, necessitating an effective cooling system. Battery Thermal Management Systems (BTMS) employed regulate temperatures, optimal performance. Among various methods, liquid-based BTMS demonstrates superior performance compared phase-change materials (PCM) air cooling. However, weight liquid coolers, due volume coolant required, can add substantial battery, impacting overall vehicle efficiency. This paper investigates potential use mini channels integrated into plates applications. The study utilizes finite element method (FEM) simulate fluid flow processes in systems operating at C-rates. findings show that this novel effectively maintains temperatures below 40C, offering promising solution current limita... Read More

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Efficient thermal management of lithium-ion batteries is crucial for electric vehicle safety and performance. This study investigates immersion cooling in serpentine channels 18650 batteries, aiming to identify key factors affecting maximum battery temperature (Tmax) pump power (Pw). A Box-Behnken experimental design implemented with Computational Fluid Dynamics simulations analyze responses Tmax Pw. Five variables are defined: partition length (Lp), charging/discharging rate (Crate), coolant volumetric flow (V), inlet (Tin) ambient (Tamb). Statistical significance evaluated via Analysis Variance. The results show that: Tin dominated Tmax, followed by Crate, V, Lp. Significant interactions (VTin VTamb) observed. For Pw, V V extreme significance, while Lp effects were minor. Interaction LpV was significant but secondary. After optimization minimize Tave the optimal values Lp, Tin, Tamb determined be 89.5 mm, 1.08 C, 0.51 LPM, 20 C, 25.62C respectively. corresponding optimized are: = 22.87C, 21.67C, Pw 0.279 mW. Optimal requires prioritizing control suppression regulati... Read More

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Battery assembly with integrated cooling system to mitigate thermal runaway propagation and improve safety. The assembly has expandable insertion members between cells that absorb heat when filled with fluid. Temperature and gas sensors monitor cells. If temps exceed threshold or gas detected, a pump moves fluid into the insertion members to cool adjacent cells. This prevents thermal runaway spread. The insertion members also have insulation layers to minimize heat transfer between cells.

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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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Battery module with improved cooling performance for applications like electric vehicles. The module has a heat sink integrated into the lower frame to directly cool the battery cells. The heat sink has a flow path for refrigerant. The flow path has longer parallel paths between the cells versus perpendicular paths. This configuration allows direct cooling of the cells with better cooling efficiency compared to indirect cooling through a separate heat sink. The integrated heat sink also improves space utilization compared to a separate heat sink.

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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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Research and development in batteries has resulted a boom the production of electric vehicles. Considered environmentally friendly, these vehicles are on rise due to developments battery chemistry. But clear problem is associated with batteries: temperature. These tend get hot as more current gets extracted from them. Ongoing research made it possible decrease temperature using various methods. so many methods available only one/two select, becomes difficult choose one. Using strong method can take energy while docile one will not do its job properly. Our project based selecting for an vehicle, designing pack, calculating heat load suitable cooling validating through finite element analysis. This help understand how selected.

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Battery module design for electric vehicles that improves cooling and stability of the battery cells. The module has upper and lower frames around the battery cells, with heat transfer members that connect to cooling channels. The frames support the cells to prevent expansion damage. The upper and lower frames have bending parts that join the side panels. The lower frame also has a flange around the cover plates. This provides a sealed, rigid structure with cooled upper and lower cell areas. The frames and heat transfer members enhance cooling by direct contact with the channels. It improves stability by supporting cell expansion and prevents internal fires spreading between modules.

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Microchannel heat sinks are widely used in thermal management systems due to their compact design and efficient transfer. To further enhance performance, this study uses numerical simulations explore the transfer characteristics of rectangular, triangular, trapezoidal, circular microchannels while maintaining equal cross-sectional areas. At Re = 900, triangular microchannel demonstrates optimal performance (HTP) but weakest hydraulic with a 5.56% reduction resistance 54.45% increase pumping power compared rectangular microchannel. The exhibits worst HTP best 12.78% 32.04% power. trapezoidal similar those one. This paper provides theoretical basis for optimizing sink designs by evaluating different shapes. findings offer insights into trade-offs between efficiency helping guide future improvements applications.

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Battery pack design for electric vehicles that simplifies assembly, reduces costs, improves space utilization, and enables higher energy density compared to conventional packs. The pack has integrated mechanical and electrical fixing for the battery modules. The pack case has a tray to support the modules and a cover that attaches to the tray. The cover has electrical connections built into it that connect to the module terminals. This eliminates separate bolting and wiring steps for the modules inside the pack. The cover also has an integrated heatsink. This reduces parts count, simplifies assembly, improves space utilization, and allows higher module packing density compared to separate heatsinks and wiring.

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Battery pack with improved cooling and safety by integrating the refrigerant piping and fastening into the pack frame, preventing refrigerant leakage and minimizing damage if leakage occurs. The pack has multiple battery modules stacked in a frame with a heat sink below. The pack frame encloses the modules and has a central refrigerant pipe. A dedicated bolt connects the module frame, heat sink, and pack frame. This bolt contains a secondary connection pipe that links the pack's refrigerant pipe to the heat sink. This integrated cooling and fastening design prevents refrigerant leaks from spreading if they occur.

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Battery array design for electric vehicle packs that integrates roll-bonded cold plates into the battery array itself rather than using separate external cold plates. The roll-bonded cold plates are formed by joining two metal sheets along a bonded seam. This allows the cold plates to be integrated into the battery array support structure to directly manage the thermal performance of the battery cells. It reduces cost and complexity compared to separate cold plates. The roll-bonded plates can form one or more sides of the array structure.

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