Passive Cooling Techniques for EV Battery Protection

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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