Passive Cooling for EV Battery Temperature Control

Battery module with integrated cooling plates filled with phase change material (PCM) to efficiently cool battery cells while minimizing temperature differences between cells. The module has multiple battery cells sandwiched between heat transfer interface plates. Cooling plates filled with PCM are inserted between adjacent cells to absorb heat from them. These plates contact the interface plates to receive heat. Cooling channels are coupled to the interface plates to transfer the heat to the outside. This allows cooling the cells with minimal weight compared to conventional methods like liquid immersion.

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Battery thermal management system for electric vehicles that uses phase change material and shape memory alloy to rapidly and compactly heat and cool the battery without complex active cooling systems. The system surrounds the battery with phase change material that absorbs or releases heat as needed. A shape memory alloy part is positioned between the battery and phase change material to expand/contract with temperature changes. This allows the phase change material to fully surround the battery for efficient heating and cooling without requiring complex channels or pumps.

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Semiconductor cooling system for battery modules using phase change materials (PCMs) to improve cooling efficiency while reducing size compared to traditional systems. The cooling system involves arranging a base plate around the battery module sides to create a cavity filled with a PCM. A semiconductor cooling plate is mounted on the base plate with its cooling surface facing the PCM. This allows direct heat transfer between the PCM and the cooling plate. To enhance heat transfer, a U-shaped heat pipe extends into the PCM and connects to the cooling plate. This allows efficient heat transfer between the PCM, cooling plate, and heat pipe. A cover plate surrounds the PCM cavity and contains fins for additional heat dissipation. The fins extend out of the cover plate to directly exchange heat with the environment. The fins also have channels for air circulation. The fins, heat pipe, and PCM all provide efficient cooling without needing external cooling

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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 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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A phase change heat transfer device for battery packs that improves heat dissipation without active cooling. The device has a cavity filled with a phase change material like paraffin. The cavity size and material are determined based on pack size and power. The device is attached to the pack surface. During charging, the pack heats the cavity material which absorbs excess heat. This reduces pack temperature rise and power consumption compared to active cooling.

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Battery module, battery pack, and energy storage system design to reduce temperature rise and differences, inhibit high temperatures, and improve cooling efficiency. The design involves a phase-change heat transfer device sandwiched between the battery pack and an interface material. The device has a cavity filled with a phase-change material that absorbs/releases heat. The interface material conducts heat between the pack and device. This reduces thermal resistance and allows the pack to utilize the phase-change material for cooling. It also provides a bonding layer to fix the pack and device together. The pack can have a liquid injection port for filling the device with phase-change material.

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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 module with improved thermal management that utilizes phase change material to absorb/release heat without requiring extra space. The module has battery core holes and phase change material holes arranged in a regular pattern. The phase change material columns are cylindrical and fit in the same-sized holes as the battery cores. This allows efficient utilization of space while still providing thermal management. The phase change material has a lower melting temperature than the battery cell operating temperature to effectively absorb/release heat.

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Battery module with improved thermal management for preventing overheating. The module has a regular arrangement of phase change material (PCM) holes interspersed between the battery core holes. This allows the PCM to absorb and release heat while making better use of space compared to surrounding the battery with a separate PCM block. The PCM holes can be cylindrical in shape for better packing density.

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Battery unit for hybrid or electric vehicles that efficiently thermally regulates the battery cells without unnecessary energy losses. The battery unit has an adiabatic enclosure around the cells to isolate them from external temperatures. To heat the cells in cold weather, a passive heat transfer member with a working fluid changes phase from liquid to vapor inside the enclosure when the cells get too cold. Gravity returns the fluid to the liquid phase when it condenses on an external cooling device. This eliminates reheating of cooling fluid and provides efficient cell heating without extra energy loss.

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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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A battery thermal management system for electric vehicles that integrates preheating and cooling using phase change material (PCM) and forced convection. The system has a box containing the battery pack with PCM shells surrounding the cells. A fan provides forced airflow over the PCM. A heating pipe connects the fan to the pack. The PCM absorbs heat during charging and releases it during discharging. The fan circulates air to cool the PCM and pack. The PCM shells provide large surface area for convection and separate channels between cells.

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Heat conducting member, battery module, battery and electric device with improved pole cooling for batteries. The heat conducting member has a hollow structure with a phase change working fluid filled inside. This allows rapid cooling of the battery pole by utilizing the phase change principle of the fluid. The cooling fluid contacts the pole to quickly absorb and dissipate heat, improving pole cooling efficiency compared to solid heat conductors.

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Battery heat management device for electric vehicles that uses a phase change material (PCM) to improve cooling efficiency and prevent PCM leakage. The battery pack has a heat exchanger with microchannel plates separated by spacers. The PCM is filled between the plates and batteries to transfer heat. This prevents PCM from flowing into the battery cells. The PCM encapsulation adheres to the plates and cells. The pack also has a thermal management system with temperature sensors and a refrigerant loop. The PCM provides internal cooling without external liquid loops. The spacers insulate between cells and the PCM prevents thermal bridging. The PCM protrusions fill gaps between plates. The pack has a flexible case with higher thermal expansion than the batteries/pack for expansion accommodation.

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Battery packs, power tools, lighting fixtures, and circuit boards with improved thermal management using composite phase change materials. The devices contain a composite heat absorber made of a combination of a main body phase change material and microcapsules. The composite absorber contacts at least one battery cell, motor, lamp element, or electronic component to absorb heat during operation. This provides localized heat dissipation without needing additional heat sinks or encapsulation. The composite absorber prevents leakage and material loss compared to pure phase change materials.

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Battery design with improved thermal management to prevent overheating and improve performance. The battery has a unique ear-shaped phase change device on the upper cover near the electrode. This device absorbs heat from the electrode during charging and changes phase from solid to liquid. The liquid then vaporizes and transfers the heat to the battery housing through a heat pipe. The vapor chamber provides additional heat transfer area. This isolated ear prevents internal battery heating and allows efficient external heat dissipation.

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Battery heat sink design that prevents flowing composite phase change materials from permeating into the bottom of a battery and reducing heat dissipation efficiency. The heat sink has a battery mounting case with a heat exchange device and encapsulated phase change material. The encapsulated phase change material fills between the heat exchange device and battery cell to transfer heat. This prevents the phase change material from flowing into the battery bottom and reducing heat dissipation.

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Battery temperature control system that uses a heat pipe and phase change material to actively regulate the temperature of lithium-ion batteries. The system has a heat exchange unit with a phase change box containing a material that melts at a specific temperature. One end of a heat pipe is connected to the battery pole and the other end is inserted into the phase change material. When the battery gets too hot, the heat pipe extracts heat from the pole and transfers it to the melting phase change material. Once the material is fully melted, an active cooling unit can be engaged to further lower the battery temperature. This allows the battery to operate within an optimal temperature range.

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Heat management device for lithium batteries in electric vehicles that uses a combination of active and passive cooling techniques to maintain battery temperature within safe operating ranges. The device has a battery case filled with phase change material, which absorbs and releases heat. A fan is also inside the case to actively cool the battery. This combined approach provides efficient and continuous temperature control without relying solely on active or passive cooling methods. A temperature sensor and controller can start/stop the fan based on battery temperature readings.

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