Techniques to Make EV Batteries Weather Resistant

Battery tray design for electric vehicles that provides impact protection, weight distribution, and environmental sealing for battery packs. The tray has a molded tub component with an integral support structure and optional compartment dividers. This reduces components and potential leak points compared to separate tray and support structures. The tub surrounds the battery area to contain and protect the modules. It seals with a cover to enclose the batteries. The tub provides structural support and impact resistance while also sealing against liquids and gases.

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Battery thermal management system that optimizes heat dissipation for battery packs in electric vehicles without active cooling. The system uses sensors to monitor battery temperature and environmental conditions. It then calculates an optimal heat dissipation strategy based on factors like battery usage, ambient temperature, and airflow. This involves adjusting factors like fan speed, vent openings, and coolant circulation to efficiently dissipate heat without wasting energy on unnecessary cooling. The system can also predict future heat generation and proactively prepare the cooling system accordingly.

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Battery thermal management system for electric vehicles that combines a vapor chamber and thermoelectric cooling to improve battery life and performance under high-power charging and discharging. The system uses vapor chambers attached to both sides of the battery pack, a thermoelectric cooling plate between the chambers and a liquid cooling plate. A temperature sensor monitors battery temperature. Gaps are sealed with thermal conductive grease. The system has a coolant supply with radiator, pump and controller.

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A power battery temperature control system for electric vehicles that efficiently regulates battery temperature in both cold and hot environments while minimizing energy consumption. The system uses an insulation layer around the battery pack and a circulating medium loop with a temperature control component. This allows heating or cooling the battery pack using an external device based on temperature readings. In winter, the loop recovers waste heat from the motor or uses a natural air cooler. In summer, it uses a vapor compression refrigeration cycle or electric heating. This provides year-round temperature control without passive insulation or inefficient active heating.

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Phase change composite battery thermal management system that integrates cooling, heating, and waste heat recovery to efficiently maintain optimal battery operating temperature. The system uses a phase changer, heat exchanger, electric heater, thermoelectric converter, and valve. Air is circulated through the system to cool the battery during normal operation. In low temperatures, waste heat from thermoelectric conversion is used to heat the battery. This prevents battery degradation and thermal runaway by maintaining optimal temperature.

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Thermal management system for electric vehicle batteries using phase change materials (PCMs) to maintain consistent battery temperatures during operation and when parked in cold environments. The system has a box filled with PCMs that absorbs heat as it melts when battery temperatures rise. It also has insulated air pillows to slow heat loss. When parked in cold, the PCMs solidify releasing stored heat. This prevents battery damage from low temps during starting/charging. The PCM box connects to the battery pack, heat exchangers, pumps, tanks, radiator, and ECU to regulate battery temps.

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Battery thermal management system for electric vehicles that uses phase change materials (PCMs) to equalize and store heat in the battery pack. The system has separate modules for heat equalization and heat storage. The heat equalization module absorbs heat from hot cells and transfers it to cooler cells using PCMs. The heat storage module contains PCMs that float in a coolant tank. When the pack temperature drops, the PCMs release heat to warm the pack. This allows consistent cell temperatures and prevents capacity loss. The system also has a water supply, cooling, and heating system for active cooling/heating.

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Power battery temperature control system for electric vehicles that provides year-round temperature regulation without compromising performance or efficiency. The system uses a circulating coolant loop with a temperature control device like a heater or refrigeration cycle. It also has waste heat recovery and natural cooling options. The control strategy adapts based on vehicle state, battery temp, ambient, and motor heat. This allows optimized heating/cooling depending on conditions instead of fixed high-energy solutions.

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Long-lasting lithium iron phosphate battery pack for use in harsh temperature environments. The battery pack has a casing with upper and lower frames inside. The battery units are placed in the upper frames. Heat dissipation devices are mounted on the sides facing the gaps between adjacent battery units. This allows quick internal heating or cooling to prevent damage from operating outside the temperature range.

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Battery pack design to improve temperature uniformity and prevent aging/fire due to lithium plating. The design involves a heating plate enclosing the battery cells and a separate heating unit enclosing the plate. A control unit regulates the heating unit based on cell temperature readings to prevent excessive cell heating. This provides consistent cell temperature and prevents hotspots that cause aging and fire risk.

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Weatherproofing of EV battery system by adjusting reserve capacity based on weather forecasts. The battery controller receives weather data and checks if the current reserve capacity is sufficient to keep the battery operational under those conditions. If not, it increases the reserve capacity to prevent damage or capacity loss due to weather. This avoids situations where remote vehicles can't be moved or charged enough to prevent cold weather damage.

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Battery thermal management system with integrated fire suppression capability to prevent thermal runaway and fires in battery packs. The system uses a liquid cooling plate inside the battery pack to regulate temperatures. It also has a temperature sensing element that opens a valve when the battery core temperature reaches a threshold. This allows the coolant to flow into the battery cells and directly contact the core. If thermal runaway occurs, the coolant vaporizes at a high temperature, absorbing heat and quickly reducing the core temp. This isolates the core from air to extinguish fires. The system also has a control method to switch between normal thermal management, emergency firefighting, and joint operation modes.

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Thermal management system for power batteries in electric vehicles that improves heating and cooling efficiency, especially in cold weather. The system uses a looped power supply between the battery pack and a supercapacitor to quickly heat the battery when starting in cold conditions. It also has a liquid cooling channel and heat conduction pipes inside the battery case to efficiently dissipate heat. The system monitors battery temperature with a sensor and controls the heating and cooling units accordingly.

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Battery pack for electric vehicles that has a pressure relief mechanism to prevent gas buildup inside the pack. The pressure relief mechanism includes a labyrinth structure that allows gas to escape without allowing water ingress. The labyrinth structure prevents water from entering the battery pack while still allowing gases to be safely vented.

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Battery pack for electric vehicles that addresses reduced discharge power and poor consistency in cold weather. The pack contains two types of batteries with different discharge powers at low temperatures. The first type has lower discharge power at low temps while the second type has higher discharge power at low temps. By using a mix of these battery types in the pack, it compensates for the temperature difference between inner and outer pack areas. This improves overall discharge power and consistency in cold weather.

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Secondary battery module design that prevents coolant leakage and damage to cells. The module has a waterproof structure to prevent coolant leakage from damaging the battery cells. This is achieved through a multi-layered structure around the cells that prevents coolant from escaping.

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A battery management system that uses weather forecast data to adjust the reserve capacity level of a battery system to prevent damage from extreme conditions. The system receives weather forecasts and determines if the current reserve capacity is sufficient to maintain battery operation in the forecasted conditions. If not, it increases the reserve capacity level to avoid damage. This helps preserve battery life by preventing over-discharge in cold temperatures or overcharging in hot temperatures.

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Sealing the interface between two battery pack enclosure pieces to prevent ingress of moisture into the enclosure. The interface gasket is compressed horizontally from outside the interface rather than being sandwiched between the enclosure pieces. This allows an effective seal without the need for an interior-facing flange that would impede battery installation and removal.

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Power supply device for electric vehicles, hybrid cars, and power storage systems that prevents short circuits due to condensation and water ingress. The device has a battery stack with insulation between the battery cells and the outer case. The insulation has grooves that channel condensation and water towards drainage points. This prevents dew and water from bridging cell terminals and causing shorts. The grooves have shapes that promote capillary action.

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An electrified vehicle with a thermal management system for the battery that adjusts temperature thresholds based on battery health. The system has multiple thermal regulation levels corresponding to battery temperature thresholds. When the battery state of health is outside a predefined range, the temperature thresholds are adjusted to prioritize either battery health or vehicle efficiency. If the battery health is low, the thresholds are adjusted to maintain health. If the battery health is high, the thresholds are adjusted to reduce cooling and improve efficiency.

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Power supply device such as battery pack for electric vehicles that prevents electrical leakage due to condensation between stacked battery cells. The device uses an insulating separator with protruding rib structures on the bottom surface. When stacked, the ribs of each separator layer nest together to form a curved path that increases the creepage distance between the battery can bottoms and insulates them. This prevents dew condensation on the exterior cans from causing electrical shorts.

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Power battery system for new energy vehicles that improves low-temperature performance of lithium-ion batteries. The system uses heating layers on low-voltage lithium battery modules to prevent deep discharge and cold start issues in extreme temperatures. The heating layers are thin film resistors or plates that can be energized to heat the batteries. This prevents capacity fade and degradation in cold weather. The heating is controlled by a thermal management unit. The system can have both high-voltage and low-voltage lithium battery packs, with separate heating layers on the low-voltage pack. This allows optimizing the low-temperature performance of the low-voltage batteries separately from the high-voltage pack.

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Battery thermal management system for electric vehicles that enables efficient temperature control of the battery pack without wasting energy. The system uses a U-shaped heat pipe configuration with thermally conductive silica gel sheets sandwiched between the battery and the heat pipes. Temperature sensors, heaters, thermoelectric generators, and heat sinks are attached to the silica gel sheets. This allows efficient transfer of heat between the battery and the heat pipes, which can be actively regulated using the integrated components for temperature control.

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Refined temperature equalization control system for batteries in electric vehicles that uses Peltier modules and flexible circuit boards to precisely balance cell temperatures without complex liquid cooling systems. The system has a Peltier module between each cell and a flexible circuit board with temperature sensors. A control module connects to the battery management system. It uses the Peltier effect to actively balance cell temperatures by selectively heating or cooling cells with the Peltier modules. This allows fine temperature control of individual cells versus whole pack balancing.

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Intelligent temperature control for electric vehicle battery packs that uses a circulating water system to regulate battery temperature. The system has a heat conduction device with a silicone tube contacting the battery surface. It also has a water tank, pump, fins, and headers connected to the tube to circulate water. This allows active cooling or heating of the battery by circulating water through the tube. It prevents excessive battery temperatures in winter or summer.

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Battery pack system for electric vehicles that allows operation in low temperatures without damaging the main pack. It uses a secondary low-temperature resistant battery in addition to the main pack. The secondary pack is charged and discharged independently to heat the main pack in cold weather. When the main pack reaches normal temperature, the secondary pack is disconnected to prevent overheating. This prevents main pack attenuation and cell damage in cold temperatures. In hot weather, the secondary pack cools the main pack. The secondary pack takes over if the main pack fails.

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Self-controlled temperature battery cell, module, pack, and electric vehicle that enables internal temperature regulation without external heating or cooling. The battery cell has both self-controlling and non-self-controlling current collectors. The self-controlling collectors have heating or cooling properties. By distributing self-controlling collectors between non-self-controlling collectors, the entire cell can be temperature regulated. This reduces overall volume and cost compared to using only self-controlling collectors.

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Battery thermal management system for electric vehicles that allows efficient heating and cooling of the battery pack in extreme cold and hot environments to prevent failures and improve energy utilization. The system connects a separate air conditioning circuit to the battery circuit. In extremely cold or hot conditions, the battery pack can exchange heat with the air conditioning system instead of relying solely on the battery cooling system. This allows heating or cooling the battery pack in extreme environments that the regular cooling system alone may not be able to handle.

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Battery thermal management system for electric vehicles that improves battery life and performance in cold weather without excessive power consumption. The system has two battery packs, a lithium battery for normal temperatures and a separate battery pack for cold temperatures. A management module switches between them based on lithium battery temperature. When lithium battery is below a threshold, the separate battery pack is powered and the refrigerant subsystem is activated to heat the lithium pack using a compressor and heat exchanger. The coolant subsystem circulates coolant through the lithium pack and exchanger for preheating. This avoids cold start discharge and power loss issues. The separate pack provides initial heating without draining the lithium pack, preventing cold start degradation.

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Electric vehicle battery pack temperature control system that improves battery pack preheating efficiency and reduces charging/discharging times at low temperatures. The system uses a heat storage exchanger to store heat during charging and discharge, and a circulating pump to transfer the stored heat to the battery pack when needed. This allows preheating the battery without consuming its own power. A heat dissipation channel with a cut-off valve can also be used to redirect coolant flow for optimal temperature control. The system integrates battery pack cooling and heating functions to improve overall efficiency and range.

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System to improve low temperature battery capacity without liquid cooling. The system uses two heating loops controlled by a battery management system based on cell temperature and ambient readings. This allows selective heating of the battery pack and surrounding area to maintain optimal temperature for higher capacity at low temperatures.

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Battery pack thermal management system for electric vehicles that improves cooling uniformity and extends battery life compared to air or liquid cooling. The system immerses the battery cells in a heat exchange medium like insulating oil. When cell temperature exceeds a threshold, a refrigerant cools the heat exchange plate to cool the cells via the oil. Below the threshold, antifreeze heats the plate to prevent cell temperature drops. This allows balanced cooling of all cells without air or liquid flow issues.

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Lithium iron phosphate (LiFePO4) batteries optimized for operation in extreme hot and cold environments. The batteries have a battery management system (BMS) that monitors and controls heating and cooling elements within the battery to maintain an optimal temperature range for uninterrupted battery operation. This allows the LiFePO4 batteries to be used in environments where traditional lithium batteries fail due to temperature extremes. The BMS uses elements like phase change materials, heat exchangers, fans, thermal electric devices, and coolers to absorb or exhaust heat as needed to keep the battery temperature within the optimal range.

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Improving the performance of electric vehicle batteries at low temperatures by selectively heating sub-batteries. The vehicle battery has multiple sub-batteries containing groups of cells. Primary sub-batteries transfer waste heat to secondary sub-batteries using conductive elements. A temperature control unit can also heat secondary sub-batteries. The battery selects the hottest primary sub-battery for warmup, then switches to a sub-battery with lower temperature when any exceeds a threshold. This concentrates heating on coldest cells. After warmup, the secondary sub-battery provides power. This selective heating improves overall battery performance at low temperatures compared to full battery heating.

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High-rate battery thermal management system to improve cooling efficiency, reliability, and charging/discharging performance of high-rate batteries like lithium-ion batteries used in electric vehicles. The system uses a tooth-like heat conducting sheet between the battery cells to form a flow channel for coolant to circulate. This increases contact area with the coolant and improves heat exchange compared to just attaching the sheet to the cells. The coolant circuit connects to an external temperature control device like an air conditioner. This allows active cooling to prevent overheating and thermal runaway. The tooth-like sheet shape quickly absorbs heat from the battery and provides higher surface area for heat transfer.

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Thermal management system for lithium battery packs in electric vehicles that prevents thermal runaway propagation and explosions. The system uses a sealed enclosure with integrated cooling, heating, and fire suppression. The battery pack is inside the enclosure, which has insulation and phase change material layers. Cooling water circulates through plates contacting the battery cells. Sensors monitor individual cell voltages, currents, and temperatures. If a cell overheats, cooling water flow is increased to that area. If multiple cells are at risk, the enclosure is heated to prevent further propagation. Fire suppression activates if a cell explodes.

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Battery temperature management system for electric vehicles that uses a composite phase change material and liquid cooling to mitigate temperature imbalances between battery cells. The system includes a composite phase change material inside the battery case, a water-cooled enclosure, a water pump, a chiller, and an expansion tank. The composite phase change material absorbs heat during charging and discharging to maintain cell temperature balance. The water cooling system removes excess heat. When ambient temperature is 0-45°C, the phase change material keeps battery temperature stable. Below 0°C, the water cooling takes over. Above 45°C, the chiller and expansion tank cool the water.

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Battery thermal management system for electric vehicles that actively controls battery temperature during charging and discharging to improve charging efficiency and avoid thermal runaway. The system has a temperature acquisition subunit connected to the battery that continuously monitors battery temperature. A control subunit generates signals based on the battery temperature to a temperature control unit that adjusts heating or cooling of the battery. This maintains the battery within a stable temperature range during charging and discharging to prevent overheating and improve efficiency.

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A battery case with superior moisture resistance for electric vehicle batteries. The case is made from a polymer composite containing a moisture-absorbing filler. This reduces water vapor transmission into the battery compared to conventional plastic cases. The case can be molded into custom shapes and sizes.

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A smart battery temperature control system for electric vehicles that provides effective temperature regulation over a wide range of environmental conditions. The system uses a combination of phase change, air cooling, and liquid cooling components to maintain optimal battery temperature. A temperature sensor on the battery triggers the appropriate cooling method based on ambient conditions. This prevents battery damage from extreme temperatures and ensures optimal performance in all environments. The system can also include heating to precondition the battery before start.

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A water-condensation mitigation system for battery packs that reduces and balances pressure inside a battery housing to prevent condensation and damage. The system uses a flexible diaphragm and pressure valves to allow pressure equalization while preventing moisture ingress. This protects the batteries from overpressure and vacuum and stops humid air from entering to avoid condensation. The valves open/close based on temperature and pressure differentials.

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An automotive battery pack cooling system to prevent spontaneous combustion in extreme temperatures. The system uses a liquid cooling loop with an aluminum heat pipe connected to the battery pack. If a cell overheats and ruptures, the deformed pipe allows coolant to leak out, preventing ignition. The system also has active cooling with heaters and radiators to maintain optimal battery temperature within limits. Sensors monitor battery temperatures and a central control adjusts the cooling components.

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Adjustable temperature lithium ion battery pack that allows operation over a wide temperature range without affecting battery performance. The battery pack has an insulated shell around the battery to isolate it from external temperature extremes. This prevents overheating at high temperatures and low discharge rates at low temperatures. The insulated shell also prevents heat transfer between the battery and the pack enclosure. This allows the battery to operate at its optimal temperature without affecting the pack's overall temperature.

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Power battery thermal management system with temperature adjustment for cold and hot working conditions to improve battery life and performance in extreme temperatures. The system uses a combination of internal heating, external cooling, and temperature sensors to maintain optimal battery operating temperatures in both cold and hot environments. The battery pack has heat conduction units between cells and a thermoelectric cooling plate for efficient heat transfer. A control module detects low battery temperatures and activates internal heating. In hot conditions, external water cooling is used for additional heat dissipation. This allows adjusting battery temperatures within normal operating ranges for extended life and performance in extreme climates.

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Battery pack for temperature equalization of lithium batteries to improve battery pack lifetime and performance by individually heating and cooling each cell. The pack has an upper and lower shell with cells sandwiched between. Each cell has a heating film and a liquid cooling plate covered by an insulating plate. This allows precise cell-by-cell temperature control to balance temperatures and prevent hot spots. The battery management module collects cell voltage and temperature data to regulate heating and cooling.

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Power battery thermal management system for electric vehicles that improves efficiency and range in both summer and winter conditions. The system uses a controllable phase change heat release unit instead of traditional liquid cooling or heating in winter. The unit has a phase change material that melts when the battery generates heat in winter. This stores excess heat. When the vehicle stops, the phase change material solidifies, releasing the stored heat to preheat the battery without active heating. This avoids the need for a separate heating system in winter. In summer, the phase change material absorbs excess battery heat, reducing load on the cooling system. The system also has a temperature sensor and controllable electrode to manage the phase change process.

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Battery pack design with integrated temperature equalization to prevent uneven heating and degradation of cells. The pack has radiators on both sides of each cell, with temperature-sensitive deformable elements in the cooling channels. These elements expand or contract with temperature changes, allowing the channels to adapt and equalize heat transfer between cells. This prevents hotspots and reduces overall pack temperature variation.

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Battery pack thermal management system and control method for electric vehicles that can adapt to extreme temperature environments and optimize battery performance. The system uses a smart control strategy that selects between heating and cooling based on battery temperature and operating conditions. It involves a battery pack management module, heating module, and cooling module. The control logic chooses between heating with high-voltage electric or fuel heaters, or cooling with radiators or AC refrigeration, based on cell temperature and charge mode. This allows optimal temperature regulation in cold and hot conditions for improved battery efficiency and longevity.

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Electric vehicle battery thermal management and in-vehicle heating system that allows efficient utilization of the heat generated during ultra-fast charging and discharging of the battery pack while also providing heating for the vehicle interior. The system uses a phase change material to absorb and store the heat from the battery pack during rapid charging/discharging. This prevents excessive temperature rise in the battery cells. The phase change material box is connected to a liquid cooling plate. When the phase change material melts, it transfers the stored heat to the cooling plate. A reversing valve and water pump circulate coolant through the cooling plate and battery pack to remove excess heat. During low temperature charging/discharging, a heat pump extracts heat from the ambient air and transfers it to the battery pack. During high temperature charging/discharging, the heat is directly dissipated to the outside using a radiator.

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Power battery thermal management system for electric vehicles that provides efficient and reliable cooling/heating of battery cells without external liquid or air cooling. The system uses a Peltier patch attached to the cell, a DC/DC converter, and a battery management module. The patch has power supplied by the converter controlled by the management module using an H-bridge circuit. This allows precise temperature control by switching the patch power on/off. The converter connects to the cell terminals and the management module monitors cell conditions. The patch provides localized cooling/heating without fluid loops or external components.

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