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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