Framework for rapid design and optimisation of immersive battery cooling system

This study emphasises lithium-ion batteries, which have been the subject of extensive research due to their wide range of benefits, including extended life cycle, minimal discharge, and high energy density. However, the temperature sensitivity of the batteries presents a notable obstacle that can negatively impact their performance and longevity when operating under extreme conditions. To overcome this challenge, implementing an effective battery thermal management system (BTMS) is imperative. Battery thermal management is crucial for ensuring the safety and longevity of lithium-ion batteries, especially in high-demand applications like electric vehicles. This comprehensive review explores a variety of BTMS technologies, including air-cooling methods, liquid-cooling techniques, heat pipes, and PCM materials. While air-cooled BTMS is a safe and straightforward design, its lower heat capacity and thermal efficiency limit its use to low-capacity batteries. However, forced air-cooled BTMS is an excellent solution for high charging/discharging rates, as air flows through channels within the battery packs to optimize cooling. Liquid-cooled BTMS also shows promise, although designers must ensure the sealing cover is secure to prevent leaks. Heat pipes (HP) offer a unique approach to controlling battery temperature, while Phase change materials (PCM) thermal management is notable for its ability to absorb significant heat by latent heat. Hybrid cooling combines fins, nanofluids, PCM, and microchannels-based cooling and can significantly enhance battery performance under high charging/discharging rates. Furthermore, lithium-ion batteries are extensively used in various applications, including the Electric vehicle industry. Keeping the lithium-ion battery temperature within the optimal range is important and is accomplished by a suitable BTMS. Different methods, such as air cooling, Liquid cooling, Heat pipe, and PCM materials, are used in BTMS. An effective thermal management system and efficient battery model are absolutely necessary. Each of the techniques in BTMS has its own benefits and drawbacks. The effectiveness of thermal management configurations and methods can vary. Thus, evaluating performance and optimal configuration is crucial before implementation.

Lithium-ion batteries are facing difficulties in an aspect of protection towards battery thermal safety issues which leads to performance degradation or thermal runaway. To negate these issues an effective battery thermal management system is absolute pre-requisite to safeguard the lithium-ion batteries. In this context to support the future endeavours and to improvise battery thermal management system (BTMS) design and its operation the article reveals on three aspects through the analysis of scientific literatures. First, this paper collates the present research progress and status of various battery management strategies employed to lithium-ion batteries. Further, to promote stable and efficient BTMS operation as an initiation the extensive attention is paid towards roles of BTMS electronic control unit and also presented the essential functionality need to consider for designing best BTMS control strategy. Finally, elucidates the various unconventional assessment tools can be employed to recognize the suitable thermal management technique and also for establish optimum BTMS operation based on requirements. From the experience of this article additionally delivers some of the research gaps identified and the essential areas need to focus for the development of superior lithium-ion BTMS technology. All the contents reveal in this article will hopefully assist to the design commercially suitable effective BTMS technology especially for electro-mobility application.

Review on battery thermal management system for electric vehicles

Parametric investigation of battery thermal management system with phase change material, metal foam, and fins; utilizing CFD and ANN models

Lithium-ion batteries, crucial in powering Battery Electric Vehicles (BEVs), face critical challenges in maintaining safety and efficiency. The quest for an effective Battery Thermal Management System (BTMS) arises from critical concerns over the safety and efficiency of lithium-ion batteries, particularly in Battery Electric Vehicles (BEVs). This study introduces a pioneering BTMS solution merging a two-phase immersion cooling system with heat pipes. Notably, the integration of NovecTM 649 as the dielectric fluid substantially mitigates thermal runaway-induced fire risks without requiring an additional power source. Comprehensive 1-D modeling, validated against AMESim (Advanced Modeling Environment for Simulation of Engineering Systems) simulations and experiments, investigates diverse design variable impacts on thermal resistance and evaporator temperature. At 10 W, 15 W, and 20 W heat inputs, the BTMS consistently maintained lithium-ion battery temperatures within the optimal range (approximately 27–34 °C). Optimized porosity (60%) and filling ratios (30–40%) minimized thermal resistance to 0.3848–0.4549 °C/W. This innovative system not only enhances safety but also improves energy efficiency by reducing weight, affirming its potential to revolutionize lithium-ion battery performance and address critical challenges in the field.

An effective battery thermal management system (BTMS) of power battery module for electric vehicles (EVs) plays a decisive role in battery life, cost, and safety in use. A BTMS method for a lithium-ion battery module, which is consisting of 12 prismatic cells, is proposed based on liquid cooling in the present work. Three circuitous channels embedded with a cooling plate are studied. In addition, the reliability and scientificity of the numerical model are verified by cooling performance tests. The simulation and test for this BTMS under a 3C discharging and charging rate were performed. Meanwhile, the performance evaluations of the battery module by considering different cooling conditions and battery arrangement are investigated numerically. With the help of the numerical model and test, the effects of flow area, mass flow rate, and cell gap on the battery temperature are examined and discussed. Simulation results illustrate that the larger flow area is experienced with a lower maximum temperature. BTMS with five channels design exhibits better heat dissipation behavior, and the maximum temperature and temperature difference under 80 g/s mass flow rate is about 45°C. Then, increases of maximum temperature and temperature difference are shown under lower mass flow rate, and the peak temperature at the lowest flow rate of 2 g/s is equal to 79.89°C, while it increases to 80 g/s, the peak temperature drops down to 47.43°C. Moreover, the lower the cell gap is, the worse the cooling performance is. Consequently, this study of this paper will provide a theoretical and an experimental basis for improving the battery module thermal behavior and BTMS strategy.

Effect of mechanical vibration on phase change material based thermal management system for a cylindrical lithium-ion battery at high ambient temperature and high discharge rate

Experimental investigation on a heating-and-cooling difunctional battery thermal management system based on refrigerant

Analysis of Battery Thermal Management System for Electric Vehicles using 1-Tetradecanol Phase Change Material

<div class="section abstract"><div class="htmlview paragraph">With the rapid development of new energy vehicles, lithium-ion batteries (LIBs) have been widely used in the automotive sector. The performance and safety of LIBs in electric vehicles (EVs) are significantly influenced by operating temperature, making the development of an effective battery thermal management system (BTMS) crucial. In recent years, phase change material (PCM)-based BTMS technology has been recognized as one of the most promising solutions. Compared to traditional air and liquid cooling systems, PCM cooling technology exhibits superior cooling performance due to its large latent heat and efficient heat dissipation capabilities, while also eliminating the need for additional pump power consumption. Therefore, in-depth research on PCM cooling technology is of significant academic and practical value for enhancing the effectiveness and safety of power battery thermal management. This study investigates the effects of thermal conductivity, melting point, and thickness of composite phase change materials (CPCM) on the transient temperature of cylindrical lithium-ion battery 18650 under high discharge rates (5C) through numerical simulations. The findings indicate that: (1) The thermal conductivity significantly impacts the melting rate of CPCM and the surface temperature of the battery; increasing thermal conductivity beyond 3.5 W/(m·K) shows negligible improvement in cooling effectiveness. (2) The selection of melting point directly affects the battery temperature rise; CPCMs with lower melting points effectively prolong melting time, maintaining the battery temperature close to the melting point. (3) The thickness of CPCMs also significantly influences thermal management; in this case, a thickness of 3-4 mm has been proven adequate to meet the thermal regulation requirements of the battery under harsh conditions. This research provides a theoretical basis for the application of CPCM in battery thermal management.</div></div>

With the increasing demand for renewable energy worldwide, lithium-ion batteries are a major candidate for the energy shift due to their superior capabilities. However, the heat generated by these batteries during their operation can lead to serious safety issues and even fires and explosions if not managed effectively. Lithium-ion batteries also suffer from significant performance degradation at low temperatures, including reduced power output, a shorter cycle life, and reduced usable capacity. Deploying an effective battery thermal management system (BTMS) is crucial to address these obstacles and maintain stable battery operation within a safe temperature range. In this study, we review recent developments in the thermal management and heat transfer of Li-ion batteries to offer more effective, secure, and cost-effective solutions. We evaluate different technologies in BTMSs, such as air cooling, liquid cooling, phase change materials, heat pipes, external preheating, and internal preheating, discussing their advantages and disadvantages. Through comparative analyses of high-temperature cooling and low-temperature preheating, we highlight the research trends to inspire future researchers. According to the review of the literature, submerged liquid BTMS configurations show the greatest potential as a research focus to enhance thermal regulation in Li-ion batteries. In addition, there is considerable research potential in the innovation of air-based BTMSs, the optimization of liquid-based BTMSs, the coupling of heat pipes with PCMs, the integration of PCMs and liquid-cooled hybrid BTMSs, and the application of machine learning and topology optimization in BTMS design. The application of 3D printing in lithium-ion battery thermal management promises to enhance heat transfer efficiency and system adaptability through the design of innovative materials and structures, thereby improving the battery’s performance and safety.

Thermal performance of a lithium-ion battery thermal management system with vapor chamber and minichannel cold plate

An effective battery thermal management system (BTMS) is of great significance to ensure the safety and efficiency of lithium-ion batteries (LIBs). Both the temperature properties and lightweight are essential to the BTMS in electric vehicles. To fulfill these targets, a direct contact liquid-cooling system with multichannel is designed for the LIB module, and the simulation model is established and validated experimentally. The single-factor analysis is performed to explore the individual influence of different variables, and the comprehensive effect is conducted by the gray relational analysis. Furthermore, three surrogate models, including the response surface model, the Gaussian process model, and the radial basis function model, are conducted to parameterize the temperature behavior. On this basis, the multiobjective optimization functions are established and optimized by considering the maximum temperature, temperature difference, and accessories mass ratio. The results suggest that the optimized liquid-cooling system achieves high cooling efficiency and is lightweight compared with other liquid-cooling systems. The maximum temperature can be controlled below 36 °C, while the temperature difference is limited to 0.65 °C at a 3-C discharge rate. Besides, the accessories mass ratio of the battery module is declined to 10.25%.

An experimental study of lithium ion battery thermal management using flexible hydrogel films

Employing extended surfaces for a hybrid battery thermal management system comprising PCM and refrigerated cooling air: An experimental investigation