Abstract
In recent times, electric vehicles (EVs) have been seen as an environment-friendly alternative to conventional vehicles. Lithium-ion battery packs power the EVs today due to their low self-discharge and higher efficiency as compared to the other battery chemistries. These batteries operate in an optimal temperature range. This calls for effective thermal management of these battery packs. Cold plates are a viable method for the thermal management of these packs. An active method of thermal management uses a coolant flowing through the cold plates, maintaining the battery pack temperature. Another approach to cold plate design is the use of Phase Change Materials (PCMs) as a passive cooling method. This paper suggests possible designs for the cooling plates, one using an active method of cooling and the other based on a PCM. The design considerations, thermal performance and manufacturing methods for both are discussed and analyzed. Results show that the PCM-based cold plate maintains the temperature with a very low thermal gradient for relatively shorter discharge durations, whereas the coolant flow-based cold plate shows a better performance for longer discharge durations. Finally, a 3-stage manufacturing process involving - Blanking, Indenting, and Projection Welding has been proposed to manufacture the two types of cold plates.
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