Heat Sinks for EV Battery Cooling

Battery module and pack design with integrated heat sink for better cooling efficiency and uniform cooling of multiple modules. The battery module has a housing that encloses the stacked battery cells and also integrates a heat sink with cooling passages. This allows direct contact between the cells and heat sink for enhanced cooling. In a pack with multiple modules, the integrated heat sink provides uniform cooling compared to separate heat sinks. The pack also has interconnect bus bars between adjacent modules to simplify wiring.

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A battery module frame for compactly packaging multiple cylindrical battery cells with improved thermal management and simplified cell retention compared to prior art. The frame has a central cooling plate with manifolds and channels to circulate cooling fluid. Exterior plates extend perpendicularly from the manifolds. The channels between the plates have thermally conductive layers to transfer heat between the plates and the cells. This allows efficient cooling and retention without complex mechanisms or fasteners.

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With the rapid development of battery energy storage technology, issue thermal runaway (TR) in lithium-ion batteries has become a key challenge restricting their safe application. This study presents an innovative protection strategy that integrates liquid cooling with sodium acetate trihydrate (SAT)-based composite phase change materials (CPCM) to mitigate TR and its propagation prismatic modules. Through numerical simulation, this systematically investigates mechanism optimization pathways for The results indicate pure SAT exhibits poor latent heat performance due low conductivity. In contrast, incorporation expanded graphite (EG) significantly enhances conductivity improves overall performance. Compared traditional paraffin-expanded (PA-EG), SAT-EG, 4.8 times higher than PA-EG, demonstrates more six effectiveness delaying (TRP). When combined cooling, effect is further enhanced, will not be triggered when initial abnormal generation rate relatively low. Even if experiences TR, prevented thickness SAT-EG exceeds 12 mm. Ambient temperature influences both peak timing occurrence modu... Read More

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Energy-dense modular battery pack design with integrated cooling system for electric vehicles. The battery pack has an array of parallel-surfaced battery cells in a non-conductive shell. Thermally conductive material like beads are placed between the cells and top/bottom contacts. Cooling plates with fluid channels compress the beads and surround the cells. The plates have inlets/outlets and channels arranged to distribute heat across the pack. This provides efficient cooling for high-density, compact battery packs that can be customized for various EV applications.

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ABSTRACT Heat generation during fast charging and discharging of lithiumion batteries (LIBs) remains a significant challenge, potentially leading to overheating, reduced performance, or thermal runaway. Traditional battery management systems (BTMS), such as airbased cooling indirect liquid using cold plates, often result in high gradientsboth vertically within cells horizontally across packsespecially under highcurrent discharge rates. To address these issues, this study introduces evaluates steadystate convectionbased esteroil immersion (EOIC) technique for LIBs. Numerical simulations based on the Newman, Tiedemann, Gu Kim model, aligned with multiscale multidimensional principles, were performed both single 18650 cylindrical cell 4S2P pack. Experimental validations conducted 2C 3C rates at 25C ambient temperature. The EOIC system demonstrated temperature reduction up 13C 15C pack compared natural air convection achieved 10C gradient simulation results closely matched experimental data, maximum deviation only 2C, confirming model's reliabi... Read More

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ABSTRACT The efficiency and effectiveness of a battery thermal management system (BTMS) primarily depend on the lesser heat capacity phase change material (PCM). To improve performance BTMS, bare batteries with different extended surfaces (straight arc) are considered to enhance dissipation heat, leading significant enhancement performance. In present study, numerical simulations carried out study impact influence CuO (10%) nano additive dispersion in PCM. Also, analyses by modifying geometries arc fins battery. Results reported that proposed improved life 61%90% compared conventional BTMS systems. Extended boost exchange surface area, batterytoPCM/CuO dissipation, form novel method for conduction during liquid fraction melting. This network expands increasing fin radial distance, enhancing At ambient temperature range 15C45C, PCM/CuO/fin substantially PCMbased 163%, 192%, 212%, respectively. These findings demonstrate possibility straight shapes PCM control. experimental results show how these designs optimize transport, improving control under varied operating si... Read More

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Battery disconnect unit for electric vehicles that allows downsizing while enabling both heat dissipation and insulation. The disconnect unit has a relay, busbar, heatsink, and insulating sheet. The insulating sheet is placed between the coolant plate and the joint section where the relay terminal, busbar, and heatsink are fastened. This allows close proximity of the heatsink to the coolant plate for better cooling without increasing size due to added insulation between them. It also prevents arc-extinguishing sand from fuse leakage contaminating the coolant side.

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A compact, flat battery pack design for electric trucks that allows for a low profile vehicle suitable for urban areas. The battery pack has multiple vertical battery modules stacked in a flat configuration. A cooling system beneath the modules transfers heat out. This allows a low profile, flat battery pack that can be sandwiched between the frame extrusions of an electric truck platform, enabling a compact, urban-friendly electric truck design.

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Battery module with integrated, in-place formed thermal management to improve cooling without adding weight. The module has a housing with a wall containing apertures. A flowable material is applied through the apertures to contact the battery core inside. It solidifies into an in-place thermal component that conducts heat from the core through the wall to the exterior. This allows the housing material with low thermal conductivity to be used while still effectively cooling the battery.

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An interface module for connectors that provides efficient thermal management without requiring multiple components. The module has a cage that guides the connector towards the interface. The cage has a floating portion that moves into contact with a heat sink when the connector is inserted. The floating portion has apertures to allow flexibility. This directly connects the connector and heat sink without extra components like clips. The module can also have the housing itself act as the heat sink.

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Battery pack design for electric vehicles that improves energy density, mechanical rigidity, and space utilization compared to conventional packs. The pack has a unique arrangement of battery modules inside a case. Each module has battery cells arranged in one direction, enclosed in a case with beams between the cells. The modules are fixed to the cover of the pack instead of a separate tray. This eliminates gaps, beams, and covers inside the pack. Cooling is integrated into the module base plate. The pack cover has a water channel to circulate cooling fluid around the modules. This reduces heat transfer path, parts, and space compared to separate heatsinks.

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Battery thermal management systems (BTMS) ensure the safety and performance of lithium-ion batteries, which power electric vehicles. However, designing an effective BTMS is challenging due to batteries' complex behaviour sensitivity temperature variations. This review comprehensively explores current vital technologies trends in BTMS, explicitly focusing on analysing various cooling control strategies. To discuss four primary technologies: air cooling, liquid immersion phase change material (PCM) cooling. The advantages disadvantages each technology are compared terms cost-effectiveness, applicability, limitations when dealing with high-energy-density batteries. Furthermore, delves into discussion strategies data prediction methods for emphasizing importance advanced analysis optimising battery safety. Different strategies, such as passive, active, hybrid control, introduced evaluated. Data methods, artificial neural networks, fuzzy logic, machine learning, also presented discussed. comprehensive provides in-depth understanding while serving a valuable reference future research appli... Read More

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Electric vehicles (EVs) are pivotal in reducing greenhouse gas emissions and achieving sustainable transportation goals. However, lithium-ion batteries (LIBs), the primary energy source for EVs, face critical thermal management, safety, long-term efficiency challenges. This study proposes an integrated battery management system that combines a waterethylene glycol-based liquid cooling mechanism with high-conductivity copper tubing to enhance LIB performance, longevity, safety. Through COMSOL multiphysics simulations, this examines behavior under varying operational conditions. The results indicate 20% reduction temperature peaks, maintaining optimal range of 15C 35C, thus mitigating risks runaway. Experimental validation using infrared thermography imaging confirms system's efficiency, showing maximum recorded 43.48C load conditions, significantly lower than unmanaged systems. Beyond work integrates advanced strategies, including state-of-charge estimation, predictive fault diagnostics, active optimization, cell balancing. analysis further reveals proposed improves heat diss... Read More

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Abstract The increasing demand for high-performance electric vehicles underscores the need efficient battery thermal management systems to ensure optimal performance and longevity of lithium-ion batteries. However, existing cooling methods often struggle maintain uniform temperature distributions effective heat dissipation, leading degradation safety concerns. To address these challenges, this study proposes an innovative liquid-cooled, microchannel-based system manage behavior a cylindrical 21700-type pack comprising 10 cells. This work aims rigorously investigate effects varying Reynolds numbers mass flow rates on critical parameters, including temperature, uniformity, convective transfer coefficient, coolant outlet pressure drop. A three-dimensional simulation model was employed analyze hydraulic proposed systems. results demonstrate that number from 400 700 significantly enhances performance, reducing maximum 38.69 C 34.25 decreasing gradient 2.45 1.86 C. improvement increases drop 3410 Pa 3990 Pa, necessitating more powerful pumping Furthermore, investigation reveals microch... Read More

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Battery module design with improved cooling for high-current, high-temperature applications like fast charging. The module has cooling pipes between the battery cell stack and frame on both the top and bottom. This provides additional cooling paths compared to just using the bottom frame. The pipes transfer heat from the cells to the frame, improving cooling and stability.

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Battery module design to prevent chain ignition and early flame extinguishment when a cell vent ruptures due to thermal runaway. The module has a heat sink facing the cell vent openings. When a cell ignites, the vent ruptures and the heat sink water flows into the ignited cell to quench the flames before they spread. The heat sink has a thin film covering the vent area that tears as the vent opens, preventing explosion force buildup and chain ignition.

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This study experimentally analyzes the performance of a passive thermal management system using three-dimensional (3D) pulsating heat pipe (PHP) designed for pouch cell batteries in electric vehicles. The term 3D refers to complex spatial arrangement PHP, which features multiple interconnected loops arranged three dimensions maximize dissipation efficiency and improve temperature uniformity around battery pack. Lithium-ion cells are increasingly favored compact lightweight packs but managing their generation is crucial maintaining preventing failure. research investigates operational parameters 3D PHP by testing two working fluids (R134a Opteon-SF33), filling ratios (30%, 50%, 80%), various condenser conditions (natural forced convection at 5 C, 20 35 C). effectiveness was tested simulated discharge cycles, with power inputs ranging from 200 W. results show that significantly improves management. Additionally, Opteon-SF33, an environmentally friendly refrigerant, offers excellent transfer properties, making this fluid promising cooling solution vehicle batteries.

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ABSTRACT Cooling lithiumion batteries using phase change material and starshaped channel for flowing fluid is presented in this paper. The proposed design tested on six 21700 cylindrical battery cells. cells are placed a case filled with wax as material, where cooled four water channels crosssection. flow assumed to be steady, fully developed, laminar. This study conducted COMSOL Multiphysics 5.6 software, assuming lumped analysis the incompressible both water. It was shown from results that temperature lowered by range of 9.43C 11.07C when discharged 15% 4C rate paraffin wax. While 9.13C 10.51C circular channels. When carried out without any cooling method during discharge, 6 reached 39.528C, while 1 39.468C. However, after case, dropped 29.788C, 30.034C, lowest 28.440C 5. temperatures were recorded 30.146C, 30.339C, 28.996C 6, 1, 5, respectively. replaced n Octadecane wax, all approximately 27.4C. showed achieved compared other designs methods. By comparing present published results, it found good agreement previous findings shows notable impro... Read More

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Abstract Batteries employed in electric vehicles are the important components due to their significant high heat capacity and energy density characteristics. However, these batteries experience drastic temperature rise generation, which is basically affected different discharge rates. To reduce this, phase change materials around as they possess latent capacity, compactness light weight nature without necessity of additional power. In present study transfer characteristics battery pack consisting 25 arranged a with paraffin PCM cells. first part work analysis carried out by varying rates evaluate thermal It observed that increase greater quantity accumulated near cells this limited conducting capabilities PCM. avoid fin configurations designed studied melting fraction average distribution within pack. Results reported M3 layout developed most effective reducing interior buildup while maintaining an optimal time. Additional examination at includes influence rest intervals, convection, configurations. The results indicate implementing intervals augmenting convection not only diminish p... Read More

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Cooling apparatus for lithium-ion batteries that allows expansion without degrading heat transfer. The cooling apparatus has a heatsink that contacts the battery on three sides to absorb heat. It also has a clearance portion that allows the battery to expand. Additionally, the heatsink has a metal plate with a spring arm to secure the battery. The clearance prevents pressure buildup and swelling, while the metal plate prevents contact loss during expansion. An elastomer between the heatsink and battery provides thermal conductivity and compression force to maintain contact. This enables efficient cooling and prevents overheating during fast charging and discharging.

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