Heat Sinks for EV Battery Cooling

A heat exchange system for battery packs that improves cooling during fast charging and prevents overheating. The system has three parts: a main heat exchanger with multiple sections, a peripheral heat exchanger around the battery modules, and inlet/outlet pipes. The main heat exchanger is divided into interconnected sections that alternate facing opposite directions. This allows more surface area for heat exchange. The peripheral heat exchanger surrounds the modules for additional cooling. The inlet/outlet pipes connect the main and peripheral heat exchangers. The arc-shaped pipe connecting sections allows better flow through the main heat exchanger. The system provides better overall heat dissipation compared to traditional designs.

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Battery module housing design with fins and channels to improve thermal management and dissipation of internal heat. The housing has a grid of fins extending from the walls. The fins absorb heat from the battery cells and dissipate it to air. The fins have channels between them to facilitate airflow. This allows natural convection cooling to distribute the heat more evenly. A heat sink can also be used to absorb heat from the fins and further enhance dissipation.

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Battery pack cooling system for electric vehicles that improves heat dissipation while avoiding short circuits and phase change material leaks. The system uses a centralized heat sink box with composite phase change material between the battery pack and the heat sink. Thermal conductive sheets between adjacent battery cells connect them to the heat sink. This allows heat transfer from the cells to the sink without risk of contact. The heat sink can also have a cooling channel. This centralized cooling reduces cell temperatures, prevents thermal runaway, and avoids issues of phase change materials melting or leaking.

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New energy storage battery pack design to improve temperature uniformity and cooling efficiency for better battery performance and lifespan. The battery pack has a base with a serpentine cooling plate on top that wraps around the battery cells. Each cell has a thermal conductive sheet on one side. Heat dissipation fins are on the other side. Side plates fit against the serpentine cooling plate. Guard plates connect the side plates. This configuration allows coolant to flow through the serpentine plate to cool the cells evenly. The fins directly contact the cells for faster heat transfer.

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Battery design with improved safety by dissipating internal heat more effectively. The battery has a housing, cell, pole element, and heat sink. The heat sink is attached to the housing to quickly discharge heat from the battery. By adding the external heat sink, it prevents excessive heat buildup inside the battery which can improve safety and reliability compared to just using an internal cooling plate.

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Battery pack design to improve battery cooling and reduce vehicle cooling system size. The battery pack uses a dual cooling system with a heat sink containing a phase change material (PCM) to absorb battery heat. This reduces the need for large radiators and pumps in the vehicle cooling system. The heat sink has a plate with grooves forming flow passages filled with cooling fluid. A PCM-filled receiving area connects the flow passages. This allows rapid cooling by fluid flow and slow cooling by PCM phase change. The heat sink plates sandwich between covers. The pack uses multiple identical heat sinks, each with its own fluid inlet and outlet pipes. This allows parallel cooling paths. The fluid flows between heat sinks through straight sections. This layout reduces overall cooling system size compared to a single large radiator.

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Battery pack with improved heat dissipation performance by using a heat dissipation member between adjacent battery cells that has a smaller height first area compared to a larger height second area. This creates a path for coolant to flow between the cells. The coolant is supplied to or drawn from the pack module, allowing it to flow through the heat dissipation member path and cool the cells. This provides secondary cooling to prevent damage to the cell cases by capturing the heat transferred from the cells and evaporating the coolant to generate steam. The steam then condenses and flows back through the member to the coolant source.

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Lithium-ion battery design for electric vehicles that eliminates the need for external cooling systems by maximizing heat transfer through the stacked battery cells themselves. The cells have discrete planar layers with larger surface area in the horizontal direction than vertical. This allows more heat transfer in the horizontal plane compared to vertical, promoting heat dissipation. The cells also use ceramic separators and solid electrolytes instead of flammable electrolytes. Additionally, external heat sinks can be added around the cells. The optimized cell design and internal heat transfer components allow adequate cooling without external coolant.

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A compact, efficient thermal management system for cylindrical batteries that uses heat pipes and a unique fluid flow arrangement to uniformly cool and heat multiple batteries in a compact pack. The system has a grid layout with batteries spaced apart and heat pipes connecting adjacent batteries. Fluid flows through the pipes and heat transfer plates in a diagonal pattern to evenly distribute cooling/heating between batteries. The diagonal flow reduces temperature extremes compared to parallel flows. The compact grid design allows more batteries while avoiding rigid contact issues of flat plates.

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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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Battery thermal management module for electric vehicle packs with high temperature uniformity using heat pipes and phase change materials. The module has a liquid-cooled plate, battery cells on top, and heat pipes between columns. The heat pipes have vertical sections in the box and flat sections on the plate. Corrugated plates distribute lateral heat. Phase change material fills the box to quickly transfer heat to the pipes and plate. This improves lateral and longitudinal temperature uniformity of large, high-density battery packs.

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Heat dissipation structure and battery pack design to improve heat dissipation efficiency of batteries, especially for high power applications like electric vehicles. The heat dissipation structure uses a heat exchange plate sandwiched between a liquid storage member and a heat conductive member. The batteries have liquid cooling channels connected to the storage member, and heat is transferred from the batteries to the storage member. The exchange plate then conducts the heat to the heat conductive member, which is in contact with the coolant. This allows direct heat transfer from the batteries to the coolant, increasing heat dissipation efficiency compared to prior designs where the heat exchange plate had limited contact area with the coolant. The improved heat dissipation enables higher power batteries without overheating issues.

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Power battery module with integrated thermal management for high-density, high-power electric vehicle batteries. The module has heat pipes between the battery cells and a connected liquid channel. Both sides of the heat pipes are tightly attached to the cell's current collectors to reduce thermal resistance. This allows efficient heat transfer between the cells and liquid. An external fluid circulates through the channel to cool or heat the cells as needed. The integrated thermal management inside the battery pack improves cooling/heating speed, prevents cell-to-cell thermal runaway, and enables higher energy density packs.

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A heat dissipation system for battery packs with improved cooling performance and adjustability compared to conventional battery pack cooling. The system uses star-shaped heat pipes that are inserted between the battery modules in the pack. The star-shaped configuration allows the pipes to be closely attached to the battery cylinders and traverse the entire pack. This provides better heat transfer compared to flat pipes. The star-shaped shape also matches the curvature of the battery cells. The pipes can be adjusted to optimize cooling based on operating conditions. The pipes have a steam cavity with working fluid and liquid-absorbent cores in the corners. This allows natural convection cooling and condensation when ambient temperatures are low, while a refrigeration system can be engaged when ambient temperatures are high.

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Battery assembly with improved cooling efficiency to prevent local overheating of battery cells and extend life. The assembly has a cooling water channel, a case, battery pack, first heat transfer between cells, and a second heat transfer on top of the case. The second heat transfer covers the case side with inlet/outlet ports and moves heat from the discharge port towards the inlet to reduce temperature differences between cells. It stacks below the center of the case and avoids the middle to prevent shortening. This prevents partial overheating and uniformly cools the cells.

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Heat exchanger assembly for batteries to improve cooling and heating rates for higher rate fast charging. The assembly has multiple heat exchange plates sandwiched around the battery sides and bottom. This allows simultaneous cooling/heating of all three battery surfaces. The plates have internal channels for fluid flow and valves to control cooling/heating rates. The assembly can be integrated into a battery pack or vehicle compartment to efficiently heat/cool the battery during charging/discharging.

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A battery pack thermal management system that effectively cools battery cells and surrounding components to extend cell life. The system involves a cooling element with heat exchange surfaces on both sides. One side contacts battery cell terminals, hotspots, and busbars, and the other side contacts circuit components. Thermal transfer channels in the element allow cooling fluid flow. Interface materials between the element and components provide electrical insulation while enhancing heat transfer. Extensions on the element contact cell ends for additional cooling. This integrated cooling element and interface design efficiently extracts and conducts heat from critical cell and circuit areas.

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Thermal management component, battery module, and battery pack design for uniformly dissipating heat and improving heat dissipation efficiency in batteries. The thermal management component uses a unique layout of heat exchange elements enclosed in tanks to surround the batteries. It has elongated first and second elements extending perpendicularly, with intermediate third elements connecting them. This surrounds the batteries and provides enclosed tanks for cooling. This configuration provides more uniform cooling compared to bottom cooling plates, especially for expanding batteries. The module and pack designs use this component to house and cool the batteries.

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Thermal management device for batteries in electric vehicles that provides improved cooling and temperature uniformity compared to prior art solutions. The device uses heat pipes to efficiently transfer heat between the battery cells and external cooling/heating sources. It has multiple heat exchange elements, one for each battery cell side, with sealed cavities containing a heat transfer medium. A separate element with a pipe section connects to external cooling/heating sources. This allows the cell-side elements to act as evaporators and the external element as a condenser. The sealed pipe prevents heat transfer limits. The device also has features like baffles, finned elements, and staggered ribs to improve heat exchange and temperature uniformity.

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A new energy vehicle battery pack cooling system with improved heat dissipation and stability. The cooling system uses a sandwich structure with a lower case, upper case, heat conduction components, heat dissipation component, and battery modules between them. The heat conduction components have flexible bags filled with heat-conducting fluid to absorb heat from the battery modules. Heat-conducting copper tubes with fins inside the bags transfer the heat to the dissipation component. This allows efficient heat transfer from the battery modules to the dissipation component for cooling. The flexible bags also buffer and fix the modules. The copper tubes with fins further improve heat exchange with the fluid. The dissipation component has fins and vortex-shaped plates for enhanced air cooling.

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