Liquid-Cooling for EV Battery Temperature Control

Battery cooling plate design to improve cooling uniformity and battery performance in electric vehicles. The cooling plate has a unique flow path configuration to distribute coolant flow more evenly across the plate surface. The coolant enters and exits along one edge, with a main section of the flow path extending along the other three edges. This main section separates the coolant flow from the plate edges. This prevents coolant heating progression that can cause temperature gradients. The plate also has turbulating inserts between the walls to further mix and distribute the coolant flow.

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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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Direct liquid cooling technology has the potential to enhance thermal management performance of electric motors with continuously increasing energy density. However, direct practical limitations for full-scale commercialization. In addition, conventionally used indirect imposes higher resistance cope increased high power density motors. Therefore, this study proposes a hybrid directindirect oil system as next-generation strategy enhanced The heat transfer characteristics, including maximum winding, stator and motor housing temperatures, coefficient, friction factor, pressure drop, evaluation criteria (PEC), are investigated different spray hole diameters, coolant volume flow rates, loss levels. computational model was validated experimental results within 5% error developed evaluate characteristics. show that diameter significantly influences performance, larger (1.7 mm) reducing hydraulic while causing slight increase in temperatures. rate major impact on dissipation, an from 10 20 L/minute (LPM) stator, temperatures by 22.05%, 22.70% 24.02%, respectively. rates also resulted emp... Read More

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Thermal management system for electric vehicle battery packs that provides efficient cooling and heating without adding significant weight or cost. The system uses a network of flexible tubes connecting intake and exhaust manifolds with channels tuned for even fluid flow distribution. It allows direct contact cooling/heating of individual battery cells by conforming tubes passing between them. The system connects to a pump and heat exchanger for circulating fluid through the pack. The flexible tubes fill and bleed easily for installation. The manifold design prevents fluid bypassing and ensures full inflation.

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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 temperature regulating apparatus for vehicles that uses a heat exchanger and a radiator to regulate the temperature of an onboard battery while reducing power consumption. The apparatus has an onboard battery, a temperature regulating plate, a heat exchanger, a radiator, valves, and a control device. The heat exchanger has a heat source that allows heat exchange without using vehicle power. The control device determines if the battery temperature is above a threshold and if the heat source is mounted. If so, it opens valves to circulate the battery heat through the heat exchanger and radiator to lower temperature. This uses the heat source as a passive coolant source instead of active cooling.

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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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A thermal management system for battery packs in electric vehicles that provides uniform cooling to prevent overheating and improve battery life. The system uses a circulation pump, a cooling device, and a network of cooling pipes within the battery pack. The pipes have a first row below the pack, a second row above, and heat exchange pipes between. Coolant enters the lower row, flows through the pack, then exits the upper row. This slow flow time fully cools the pack. The cooling device cools the returning coolant. The lower row below the pack ensures complete cooling.

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Thermal management system for electric vehicles that allows both battery cooling and heating using a single chiller component. The system has a battery circuit, drive circuit, and refrigerant circuit. The chiller can operate in cooling mode to extract heat from the battery during charging or discharging, and in heating mode to provide heat to the battery during cold weather starts. This eliminates the need for a separate battery heater component. The chiller can switch between cooling and heating using a combination valve to redirect the refrigerant flow path.

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Cooling mechanism for square prismatic batteries that improves cooling efficiency compared to conventional designs. The cooling mechanism has a liquid-filled cavity on the battery mounting plate, connected to inlet and outlet pipes. A flow regulating valve controls liquid flow. This allows direct cooling of the battery cells by contacting the bottom of the cells. The liquid quantity is adjustable to match cell temperatures. The total flow assembly connects multiple battery cooling systems to a centralized water circuit.

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Liquid cooling energy storage electric box composite thermal management system with heat pipes for heat dissipation of lugs. It aims to improve heat dissipation efficiency and uniformity for battery packs by using heat pipes between lugs and liquid cooling plates inside the pack enclosure. This allows direct cooling of the lugs where high temperatures occur, as well as overall pack cooling. The heat pipes transfer heat to the upper and lower cooling plates which are connected to an external liquid supply and return system.

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An active liquid cooling system for electric vehicle battery packs using high thermal conductivity aluminum cold plates with unique design features to improve cooling performance, uniform temperature distribution, and avoid thermal runaway. The cold plates have a height of 30-60 mm and a contact angle of 120-150 degrees between the plates and battery cells. This design lowers the highest pack temperature, provides uniform cooling, and handles rapid discharge and load changes. The increased plate height and angle in the flow direction enhances cooling by lowering temperature gradients and providing more surface area.

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A thermal management system for electric vehicles that allows efficient battery cooling and passenger cabin heating/cooling across a wide range of operating conditions. The system uses a common cooler to exchange working fluids between the battery thermal management circuit and the refrigerant circuit. This allows the battery cooler to be used more efficiently and fully utilize the heat exchange area. The system can switch between three modes: 1) simultaneous battery and cabin cooling, 2) battery heating using the battery cooler, and 3) cabin cooling using the battery cooler. Valves and expansion valves selectively route the fluids through the cooler and components like the battery pack and radiator to achieve the desired mode.

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Liquid cooling system for electrochemical batteries to prevent overheating and thermal runaway. The cooling system uses a specialized liquid cooling board inside the battery pack. It has channels with air-cooled components like L-shaped pipes with pivoting fans. The pipes connect to a booster pump, water tank, and heat exchanger. The pipes can tilt and rotate for optimal cooling. It prevents crystal growth in the channels by using air-cooled sections. The pipes pivot to move the fans for better cooling. A tilting frame allows adjusting the board angle. This multi-stage liquid cooling system with air-cooled sections and movable fans provides efficient cooling for high-power batteries.

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Battery thermal management system for electric vehicles that improves temperature uniformity inside the battery pack. The system uses two cooling loops, one bypassing some components like heaters and radiators, to circulate coolant. A valve switches between loops. The bypass loop has lower pressure drop. Periodically switching flow direction in both loops further reduces temperature gradients.

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An energy storage device with improved cooling efficiency for high power density battery modules. The device has two vertically stacked liquid cooling plates that are thermally connected to the battery module's sides. The plates have parallel channels for circulating cooling fluid. The channel lengths on the first plate for some sections are shorter than others. This unequal channel length configuration allows better temperature uniformity by reducing temperature differences between sections. It improves cooling efficiency by reducing hot spots in high power density battery modules. The shorter channels on the first plate compensate for higher temperatures generated at the bottom of the module.

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Battery thermal management system for electric vehicles using immersion cooling to efficiently cool the batteries and prevent overheating. The system involves submerging the batteries in a non-conductive liquid, circulating the liquid to extract heat, and using an external heat exchanger to further dissipate it. This provides a closed loop immersion cooling system for the batteries. The liquid submergence and circulation prevents direct air cooling that can be less effective. The liquid cooling allows higher battery density and capacity without overheating.

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Energy storage battery temperature control system to prevent thermal runaway and improve battery pack consistency in electric vehicles. The system uses an internal cooling loop with a liquid supply and return pipeline, a temperature regulating device, and a cooling unit. It injects cooling liquid into the battery pack if a cell goes out of control to prevent thermal runaway. It also has a fire-fighting device that can spray cooling liquid into the pack from above if needed. This allows rapid cooling and suppression of runaway cells. The internal loop reduces heat transfer links compared to air cooling and improves temperature uniformity.

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Battery thermal management system for electric vehicles that improves battery module output efficiency by using a closed-loop refrigerant cycle with heat recovery and regeneration. The system has a thermal management unit, cycle unit, heating unit, cooling unit, sensing unit, and control unit. The cycle unit circulates a first heat exchange medium to the battery module. The heating unit transfers refrigerant from the compressor to heat the battery. The cooling unit transfers refrigerant from the evaporator to cool the battery. The control unit selectively opens/closes the heating and cooling units based on battery temperature. This allows regenerating heat from the cooling unit to heat the battery instead of wasting it. The refrigerant cycle also allows separate cooling/heating paths to share pipes for simplicity.

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Circulating liquid cooled lithium battery pack with improved heat dissipation and uniformity compared to conventional battery packs. The pack has an internal cooling system where the battery housing is filled with a cooling liquid that circulates through a pump and piping. This allows more uniform cooling and higher heat dissipation compared to external liquid cooling methods. The pack consists of a battery cell assembly inside a housing filled with the circulating liquid. The liquid is pumped through pipes to circulate around the cells for cooling. This provides better cooling and temperature control compared to air or phase change materials.

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