Passive Cooling Techniques for EV Battery Protection

Battery pack design for improving thermal management and shock protection without increasing pack thickness. The pack has a module case that covers a protection circuit mounted on the battery cell. The module case has a stepped shape with a narrow region between the cell and the case, and wider regions on either side. The protection circuit is sandwiched between the narrow region and wider regions. This allows the module case to fit snugly against the cell and exterior housing, preventing heat transfer gaps. The stepped shape prevents interference with the housing seals. The narrow region also helps dissipate heat from the cell into the wider regions for better thermal management. The module case can be secured to the cell using adhesive tapes with high thermal conductivity to improve heat transfer.

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Passive cooling article with high emissivity elements facing upward on one side and low emissivity elements facing downward on the other side. This allows passive cooling by radiating heat to the sky during the day. The high emissivity elements have high absorption in the infrared (IR) range and low reflection in visible light, while the low emissivity elements have low absorption in the IR and high reflection in visible light. The article can be applied as a cool wall surface on vertical structures like buildings or vehicles to reduce internal temperatures without active cooling.

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Passive cooling device that uses a thin film coating on a substrate to cool without electricity. The coating absorbs infrared radiation and emits it back into space through a window in the Earth's atmosphere. This cools the device by radiating heat into space. The coating is optimized to have high absorption above 4 μm wavelength and low absorption below 2 μm. This selective absorption enhances the cooling effect. The coating is made of polydimethylsiloxane (PDMS) and can be fabricated using simple solution coating techniques. The coating is applied to a substrate like aluminum or gold. By manipulating the beaming effect of the thermal radiation, it reduces temperatures by 9.5°C in lab tests. An outdoor setup in Buffalo, NY achieved continuous all-day cooling with a 11°C temperature drop and 12

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A passive cooling system for buildings and electronic enclosures that provides enhanced cooling capacity compared to traditional passive cooling. The system uses a heat exchanger with multiple coils and tubes filled with working fluid. The coils are mounted at angles to maximize heat transfer. This allows natural convection and radiation cooling without forced air or pumps. The angled coils improve fluid flow and heat transfer compared to horizontal coils. The multiple coils and tubes increase the heat removal capacity compared to single-tube thermosiphons.

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Additively manufactured thermal management structure for battery packs in electric vehicles that provides efficient cooling while reducing weight compared to traditional cooling systems. The structure has interconnected lattice walls surrounding the battery pouch. Outer walls contact the pouch sides, an intermediate wall contacts the pouch interior, and a bottom wall supports the pouch. The lattice structure allows heat transfer between the walls while minimizing material usage. The additive manufacturing process enables complex lattice geometries that can't be easily formed using conventional manufacturing methods.

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A secondary battery pack for electric vehicles that improves thermal management to prevent runaway cell temperatures and propagation of thermal events. The pack uses a syntactic foam made of hollow glass beads in a silicone binder to insulate the battery cells. This foam provides better low-temperature insulation compared to standard foams. It also minimizes thermal propagation between cells. The pack can have coolant channels and heat dissipation members to further manage cell temperatures. The syntactic foam also helps dampen drivetrain oscillations.

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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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Power battery thermal management system that integrates cooling and power generation using phase change materials and heat pipes. The system sandwiches the battery between layers of phase change material, with a heat pipe connecting them. A cooling unit with a fan draws air through an air channel. The battery, PCM, and heat pipe temperatures are monitored. When battery temp rises, the fan starts to cool. When PCM melts, the fan stops. This allows battery temp control and PCM melting/solidification. The PCM provides latent heat storage and thermal insulation. The heat pipe transfers heat from battery to PCM. The fan extracts heat during cooling. The PCM melting provides extra cooling during discharge. The PCM solidification generates heat during charging. The system provides efficient, uniform battery temp control with integrated power generation.

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Power battery temperature management system to improve heat dissipation and heating performance of power batteries like those used in electric vehicles. The system uses a removable battery box with a detachable top cover. Inside the box, a fluid heat exchanger is mounted between the battery and the box walls. This allows circulating a cooling fluid through the exchanger to quickly cool the battery. An electric heating film can also be added between the exchanger and the battery to quickly heat it. This enables rapid cooling in high temperatures and rapid heating in low temperatures. The removable box design allows easy access for maintenance.

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Thermal management system for batteries using a low melting point metal phase change material to passively regulate temperature without active cooling. The system has a shell with a cavity to hold the battery, a heat transfer element made of the same low melting point metal, and a storage cavity filled with the phase change material. As the battery heats up, it transfers heat to the heat transfer element which melts the phase change material. As the battery cools, the solidified phase change material absorbs heat. This provides passive thermal management in confined spaces without active cooling.

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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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A secondary battery pack for electric vehicles that improves thermal management to prevent thermal runaway and propagation between cells. The pack uses a syntactic foam insulation made of hollow glass beads in a silicone binder. This foam provides thermal insulation and minimizes temperature differences between cells. It also has low water absorption to prevent swelling in wet conditions. The pack also has thermal barriers and spacers to isolate cells and prevent thermal propagation. The spacers maintain cell position during thermal events. The pack may also have coolant channels to dissipate heat. This comprehensive thermal management strategy mitigates cell-to-cell thermal effects and risks.

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Heat dissipation device for high-power battery packs that provides improved cooling efficiency and uniformity compared to existing solutions. The device surrounds the battery pack and has a heat exchange component with fluid channels that contact the battery surfaces. The channels have an arc shape to conform to the battery contour. This allows thorough heat transfer from the battery to the fluid. The device also uses a heat conduction component between the battery and the exchange component. This enables efficient heat dissipation from the battery pack without complex liquid systems or phase change materials.

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Temperature regulating device for battery cells, batteries, and battery modules to prevent overheating and improve safety. The device has a heat conductive member with a flow cavity for circulating cooling medium. A semiconductor heat exchanger attaches to the conductive member with one side thermally connected to the cell. The other side exchanges heat with a cooling medium. This allows direct cooling of the cell through the semiconductor while maintaining insulation. The battery core wraps the device. The battery has an additional dielectric contact and cooling channel. The battery module has a central plate connecting the cooling channels of multiple batteries.

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A battery thermal management system that addresses both low-temperature heating and high-temperature cooling needs. The system uses a combination of phase change materials, flat heat pipes, thermoelectric cooling, and vapor chambers. The phase change materials absorb and dissipate heat during charging/discharging. Flat heat pipes transfer heat between battery packs. Thermoelectric cooling plates provide active heating or cooling. Vapor chambers capture and transport heat. This compact, versatile system improves battery temperature control for optimal performance and safety in all conditions.

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Battery assembly and power supply apparatus with improved thermal management and safety features. The battery assembly has a distributed heat sink made of interconnects between the batteries. This allows equalizing battery temperatures and preventing hot spots. The heat sink is integrated into the battery pack design. The pack also has a thermal exchange device with surfaces for heat exchange and a contact surface in thermal contact with the interconnects. This allows transferring battery terminal heat to the heat sink. This aids cooling and prevents terminal overheating. The pack has battery management circuitry and a housing with a discharge chamber to contain thermal runaway. The housing has insulated upper walls to prevent air exchange and improve temperature sensing accuracy.

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Thermal management system for battery packs, particularly electric vehicle battery packs, that provides improved cooling and heat distribution compared to existing systems. The system uses a framework with encapsulated graphite plates sandwiched between battery pouches. The plates extend between adjacent pouches to form a network of thermal paths. Working fluid flows through channels in the framework and plates to extract heat from the batteries. This allows uniform cooling across the pack and prevents hotspots. The plates also spread the heat across the pouch surface for more even temperature distribution.

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Supporting housing for battery compartments of electric vehicles that uses flat metal sheets for cost-effective mass production, while integrating passive thermal management and other functions. The housing consists of deep-drawn shells that fit together to form a double-floor compartment. The batteries sit on the double-floor separated from the thermal management system. Coolant channels in the outer shell indirectly cool/heat the compartment. Sensors can be integrated into the double-floor for battery status monitoring. The double-floor design isolates the batteries from the cooling system to prevent short circuits. The thin metal sheets have high thermal conductivity for efficient heat transfer.

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Battery thermal management system that uses a combination of thermoelectric cooling, phase change materials, and liquid cooling to efficiently manage battery temperatures. Multiple identical thermal management units are coupled together. Each unit has a phase change material module, a liquid cooling integrated support module, a thermoelectric cooling module, a liquid cooling cold module, and a temperature measurement module. The system dynamically switches between modes based on battery temperature conditions to optimize cooling and heating. This allows fast cooling, precise temperature control, and preheating without adding extra components compared to single cooling methods.

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Battery temperature control device for improving battery cooling and uniformity, using two-stage phase change materials (PCMs) and liquid cooling. The device has square batteries stacked with interleaved PCM plates and a liquid cooling plate surrounding them. The PCM plates have separate layers of metal and organic PCMs. This allows the batteries to be sandwiched between PCMs with different melting points. The metal PCM absorbs heat at lower temperatures and the organic PCM absorbs heat at higher temperatures, providing two-stage temperature control. The liquid cooling plate circulates fluid around the batteries to further dissipate heat. This provides additional cooling and helps prevent local hotspots.

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Battery pack with improved temperature uniformity using a composite thermal interface layer between the battery cells and cooling plate. The composite layer has regions with different thermal conductivities. A lower conductivity region covers areas where temperature differences are small, to reduce heat exchange. Higher conductivity regions cover areas with larger temperature differences, to improve heat exchange. This customized thermal interface improves temperature uniformity across the battery pack.

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A battery thermal management system that uses phase change materials (PCMs) to improve battery performance and safety by eliminating the need for active cooling. The system involves integrating PCMs into the battery pack design through encapsulation and embedding to provide efficient heat transfer. PCMs like paraffin waxes, salt hydrates, or organic compounds are positioned adjacent to the cells to absorb and release thermal energy during phase transitions. A temperature sensor continuously monitors the pack and a control unit dynamically adjusts heat flow through selected PCMs based on real-time data. This optimized PCM distribution ensures consistent temperature across cells without active cooling.

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Battery design for electric vehicles that reduces thermal runaway propagation between cells. The design involves placing thermal barriers between adjacent cells. Each barrier has a thermal insulator between the cell and a heat-absorbing and expanding material. The insulator separates the cell from the expanding material. The expanding material absorbs heat and expands without consuming the insulator. This prevents heat transfer between cells. If a cell has thermal runaway, the expanding material absorbs and disperses the heat, preventing further propagation.

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Battery thermal management structure using heat pipes and phase change materials to reduce parts, simplify assembly, and improve heat dissipation compared to conventional battery cooling methods. The structure is a semi-packaged design where the battery cells are arranged in a discrete array inside a box. Heat pipes with plate-shaped sections connect the cells to cooling channels. Porous lattice structures fill the channels. Phase change material fills the cells. This allows internal heat transfer through pipes and latent heat storage in PCM. Coolant circulates through the channels. In low temp, external heat warms the coolant which transfers to cells. In high temp, cells heat coolant which cools externally.

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A multi-layer device to equalize battery temperatures in electric vehicle packs with multiple modules to reduce temperature variations between batteries. The device has a first conductive layer, a thermal shell, and multiple thermally conductive partitions inside the shell. The conductive layer absorbs heat during charging and melts to circulate between the partitions. This redistributes heat to equalize temperatures between batteries.

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Battery module for uniform cooling of multiple secondary battery cells while preventing overcooling of adjacent cells. The module has a housing with secondary battery cells, a cooling plate, and a heat conductive member between the cells and plate to transfer heat. The heat conductive member has a central portion with high thermal conductivity and an edge portion with lower conductivity. This gradual conductivity decrease near the module edges prevents supercooling of adjacent cells when one is exposed to external air. The lower conductivity edge portion can have lower metal content in the resin, or pores, compared to the central portion.

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Battery cooling plate with improved thermal management for electric vehicle batteries. The cooling plate has a phase change material coated with heat conducting silica gel. The silica gel improves the mechanical strength, thermal consistency, and prevents leaks compared to the phase change material alone. The silica gel is cladded on the phase change material surface and seals it to prevent leakage when the gel liquefies during charging/discharging. This provides a reliable, leak-free cooling solution for battery modules.

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A secondary battery pack with improved thermal management to prevent propagation of thermal runaway between cells and minimize the effects of extreme temperatures. The pack uses a specific syntactic foam made of silicone rubber binder and hollow glass beads. This foam is sandwiched between the battery cells to insulate them from each other and the pack enclosure. It also absorbs thermal energy to reduce temperature spikes. The foam has low water absorption to prevent swelling in wet conditions. The pack may also have thermal management features like cooling channels, heat sinks, and spacers to further isolate cells and dissipate heat.

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Reducing thermal energy transfer between battery arrays of a battery pack to prevent venting during high temperature events. The technique involves using a phase change material (PCM) sandwiched between adjacent battery arrays and a thermal exchange device like a liquid coolant channel. The PCM absorbs excess heat from one array to prevent it transferring to the other array. This prevents one array overheating and venting due to thermal runaway, as the PCM acts as a thermal barrier. The PCM can be adhesively secured to the thermal exchange device.

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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 system for batteries like lithium-ion cells that uses a closed loop with phase change and spray cooling to prevent overheating during charging and discharging. The system has a heat exchanger to absorb heat from the battery in a partially phase-changed medium, and a condensation component where the medium condenses and reheats. Spray nozzles above each battery can activate when needed to cool it down. The loop allows continuous heat transfer and prevents thermal runaway by keeping battery temperatures in a safe range.

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Battery pack for electric/hybrid vehicles that has an integrated cooling/heating system to maintain optimal operating temperature for the cells. The battery pack uses a stack of thermally conductive heat sink plates sandwiched between inner and outer frames. The plates have fins with different configurations to transfer heat to/from the cells. Rods connect the plates to form the battery pack. The frames retain the cells mechanically and can be disengaged for service. This provides efficient thermal management to prevent performance degradation due to temperature variations between cells.

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Heat exchange module for battery packs in vehicles that improves temperature uniformity and allows better cooling and heating of individual battery cells. The module has multiple parallel heat exchange paths for each battery module instead of just one. This allows more targeted cooling and heating of specific cells. By connecting separate heat exchangers in parallel with the main heat exchange road, each cell can have its own dedicated heat exchange path. This prevents temperature gradients within the battery pack and improves overall performance and reliability.

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Battery thermal management component with adjustable cooling capacity for batteries with odd number of cells. The component has two sets of heat exchange surfaces, one for outer cells and one for middle cells. The outer cell set has larger area surfaces for better cooling. This allows customizing the cooling ratio between outer and middle cells to reduce temperature differences and improve battery performance. The component can be used in batteries with odd numbers of cells to improve space adaptability.

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Battery thermal management system that integrates heat pipes and thermoelectric refrigeration for efficient and effective cooling and heating of battery packs. The system uses a heat pipe to transfer heat between the battery and a thermoelectric cooling sheet. This allows rapid heat dissipation when the battery gets too hot, and rapid heat transfer when the battery gets too cold. The system monitors battery temperatures and controls the thermoelectric cooling sheet and water pump to maintain optimal temperatures for battery performance and safety.

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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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Cooling system for electric vehicle charging ports to prevent high pin temperatures during fast charging. The cooling is achieved without complex liquid cooling loops. The charging pins are surrounded by porous metallic cages filled with phase change material. A vapor chamber is between the base of the pins and the cages. The phase change material absorbs heat from the pins during charging, preventing high temperatures, while the vapor chamber further dissipates heat. This simplified cooling method avoids the need for complicated liquid cooling loops.

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Battery thermal management system that integrates phase change and thermoelectric cooling to efficiently manage battery temperature in both high and low temperature environments. It uses a combination of phase change materials, thermoelectric modules, and liquid cooling to provide cooling, shutdown, and heating modes. This allows the system to adapt to varying temperature requirements. The thermoelectric module can switch between cooling and heating modes based on control signals from a decision-making module. The liquid cooling flow rate is adjusted based on the thermoelectric module's cooling/heating capacity. This enables efficient cooling in high temps and preheating in low temps.

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Heat exchange assembly for battery packs that improves cooling and temperature stability in high-power battery applications. The assembly has a heat exchanger connected directly to the battery modules for better cooling contact. It also has an energy storage component with a phase change material on the side away from the modules. This allows direct cooling of the modules while buffering temperature changes. It prevents excessive heating during charging/discharging and improves pack temperature uniformity.

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Battery cooling system for high-capacity lithium-ion batteries to prevent overheating and increase battery life. The cooling system uses heat pipes and phase change materials to transfer heat from the battery poles to a heat sink. This unidirectional cooling prevents heat buildup in the batteries. A core heat pipe contacts the battery pole and transfers heat to an evaporator heat pipe. The evaporator heat pipe condenses in a phase change material or has fins for convective cooling. This allows battery poles to be cooled without active cooling devices. The cooling system can be used in large-capacity battery packs to maintain optimal battery temperatures.

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Cooling system for cylindrical lithium-ion battery packs that uses heat pipes, phase change materials, and liquid cooling to efficiently dissipate heat generated by the batteries. The system consists of a central arc-shaped heat spreader connected to the battery cells, U-shaped flat heat pipes, phase change material, a bottom plate, and a liquid cooling plate. The pipes, plate, and spreader conduct heat to the cooling plate where a liquid circulates to dissipate it. The spreader also has a hole filled with phase change material to absorb and release heat.

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Power battery thermal management device for electric vehicles that uses soft heat pipes to dissipate heat from the battery pack. The device consists of a battery pack, enclosure, cover plate, soft heat pipes, and a return assembly. The soft heat pipes are flexible sheets sandwiched between the batteries. They have a sealing outer layer, liquid-absorbing layer, structural support layer, and phase change material. The liquid-absorbing layer is made of a super-hydrophilic material. The structural support layer is breathable. The phase change material has a temperature within the battery operating range. The soft heat pipes absorb battery heat and transfer it to the enclosure. The return assembly collects the heat from the cover plate.

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Thermal management system for power batteries that reduces battery heating and cooling requirements to extend battery life. The system uses a refrigeration device, a heat preservation and heating device, and a thermal insulation and heating device. The refrigeration device cools the battery pack when needed. The heat preservation and heating device covers the refrigeration device and has channels filled with variable thermal insulation material. It absorbs excess heat from the battery pack during discharge and releases it during charge. The insulation and heating device surrounds the battery pack inside the refrigeration device to further insulate it.

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A battery cooling system for large-capacity lithium-ion batteries that reduces heat buildup without additional power consumption. The system uses a combination of cored heat pipes, gravity heat pipes, and phase change materials in a compact heat exchanger unit. The cored heat pipe transfers battery pole heat to the gravity heat pipe. The gravity heat pipe condenses into the phase change material for storage or dissipates via fins. This directional heat transfer prevents external heat from entering. The phase change material absorbs/releases heat as needed. The compact, integrated cooling system avoids active cooling devices and saves cost/space.

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Battery thermal management system that combines phase change material (PCM) and liquid cooling to improve battery temperature regulation. The system has a PCM package around each battery cell. If the cell temperature gets too high, the melting PCM loses heat dissipation capacity. To prevent overheating, a heat exchange plate in the cell connects to a liquid cooling system. If the cell temperature continues rising, cooling liquid is passed through the plate to dissipate heat. If the cell gets too cold, the plate is filled with heating liquid to prevent further temperature drop. This allows precise temperature control beyond the PCM range.

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Uniformly distributing waste heat from electric vehicle battery packs using conformable thermal interface materials. The system involves placing a flowable thermal interface material between the battery pack cells and a central coolant reservoir. The material flows around each cell to provide constant thermal contact. It then crosslinks to solidify and maintain the contact. This allows uniform waste heat transfer from the cells to the reservoir. The conformable material can be a gel or liquid polymer that flows around the cells and solidifies.

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Battery module for electric vehicles that uses thermoelectric cooling to maintain optimal battery temperature for charging and discharging. The module has a battery pack, thermoelectric elements, thermally conductive material, and a frame. The thermoelectric elements have heat absorption surfaces inside the frame and heat generation surfaces contacting the battery pack. This transfers battery pack heat to the frame to dissipate it. Heat insulation between pack sides and frame prevents direct transfer. A relay closes for cooling when heating current is low. A PTC heater increases resistance for relay closure. Switches control DC supplies. The vehicle has air ducts to guide air over the frame heat sinks for additional cooling.

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Passive heat dissipation structure for small power battery packs that provides enhanced cooling without complex systems like liquid cooling. The structure uses a heat-conducting body between battery cells to transfer heat to a top panel. The panel dissipates heat to air via convection. The panel covers the heat-conductor projection to ensure complete coverage. This integrates insulation, anti-vibration, and enhanced cooling in a compact battery pack.

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Mobile battery thermal management system for improving battery performance and safety by effectively controlling battery temperatures. The system uses a composite phase change material heat sink, cooling fan, and circulating cooling medium to manage battery temperatures. The phase change material absorbs heat from the battery when it gets too hot and releases it when it gets too cold. The fan circulates air through the heat sink to dissipate heat. The circulating cooling medium passes through the heat sink to extract heat and dissipate it externally. This comprehensive cooling system keeps battery temperatures within optimal range.

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