Battery Thermal Management System Research Articles

A comprehensive assessment of working fluids selection in heat pipe-assisted battery thermal management systems: An integrated Multi-criteria decision-making approach

A comprehensive assessment of working fluids selection in heat pipe-assisted battery thermal management systems: An integrated Multi-criteria decision-making approach

Experimental and Numerical Investigation for Optimization of a Hybrid Battery Thermal Management System based on PCM and Air Convection

Abstract This work presents the design and optimization of a phase change material (PCM) based hybrid battery thermal management system (HBTMS). In the first stage, experiments are performed to measure the battery cell temperatures under various charge rates with and without the usage of PCM. Thereafter, a numerical model is developed to conduct a parametric study on the effect of thickness of PCM layer around the battery cell. The maximum cell temperature (36.35°) and thermal nonuniformity are within the safe range for the PCM thicknesses of 6 to 12 mm. In the second stage, a parametric study is conducted in the 6S1P battery module to optimize the spacing between the cells at constant inlet velocity. The maximum temperature is within the optimal range when the cell spacing is 10 mm. At the constant cell spacing of 10 mm, increase in inlet velocities from 0.25 m/s to 2.5 m/s gradually improves the thermal non-uniformity. The maximum temperature and thermal non-uniformity for 6S1P battery module is found to be 42.07° and 1.17° respectively. In the third stage, 6S1P battery module is optimized for PCM thickness, cell spacing and inlet air velocity. It is found that effective thermal management is possible with PCM based HBTMS at low airflow rate of up to 1.5 m/s. The optimized PCM based HBTMS shows 46.59% and 40% reductions in PCM mass and air flow rate respectively.

A novel pulse liquid immersion cooling strategy for Lithium-ion battery pack

Ensuring the lithium-ion batteries’ safety and performance poses a major challenge for electric vehicles. To address this challenge, a liquid immersion battery thermal management system utilizing a novel multi-inlet collaborative pulse control strategy is developed. Moreover, different cooling methods (cooling structures, immersion coolants and pulse control method) are numerically investigated to assess their impact. Compared with other structural schemes, the battery module using baffles with fish-like perforations for the 5-in and 5-out scheme demonstrates superior cooling capability while reducing external power consumption. Furthermore, the utilization of FC-3283 exhibits better comprehensive performance compared to AC-100 and mineral oil. Notably, in terms of pulse cooling, when the output ratio reaches 50 %, the battery pack temperature can not only be maintained within a reasonable range, but also the time-averaged pump power consumption decreases by 87.6 % compared to the bottom inlet and top outlet scheme. At the same average flow rate, the liquid immersion battery thermal management system with output ratio of 25 % is the optimal choice for the trade-off between cooling performance and flow resistance, and compared with the bottom inlet and top outlet scheme, the maximum temperature and maximum temperature difference decrease by 23.7 % and 13.9 %, respectively.

Battery Thermal Management System in Electric Two-Wheelers

This work documents the design of a battery thermal management system for an electric vehicle in which a liquid cooling system was designed for a 24V Li-ion battery pack. Then, a thermal simulation was performed by using one-dimensional heat transfer modelling using Solidworks. This model also consists of the design of a heater, pump and evaporator to determine the total energy consumption of BTMS. The results indicate that the battery temperature is maintained between 20-30 °???? for various driving profiles with a maximum energy consumption of 0.3%.This work documents the design of a battery thermal management system for an electric vehicle in which a liquid cooling system was designed for a 24V Li-ion battery pack. Then, a thermal simulation was performed by using one-dimensional heat transfer modelling using Solidworks. This model also consists of the design of a heater, pump and evaporator to determine the total energy consumption of BTMS. The results indicate that the battery temperature is maintained between 20-30 °???? for various driving profiles with a maximum energy consumption of 0.3%.

Thermal management for the prismatic lithium-ion battery pack by immersion cooling with Fluorinated liquid

This study constructs a novel FS49-based battery thermal management system (BTMS), proposing an optimization method for the system energy density and an indirect control method for the system cooling capacity. The boiling of dielectric refrigerant occurred at the battery surface, which provided strong and uniform cooling for each battery cell. The results show that the peak temperature difference of liquid immersion cooling (LIC) module during 1C rate discharging and charging was reduced by 91.3% and 94.44%, respectively, compared to the natural convection (NC) module. The reduction of temperature nonuniformity greatly reduced the state of charge (SOC) inhomogeneity of different cells within the module. Moreover, the energy density of LIC module can be optimized by reducing the cell spacing and liquid filling ratio. Comparing with 100% filling rate, the module maximum temperature corresponding to 25% filling rate (with wick) during 2C rate discharging is only increased by 1.6℃, however, the module peak temperature difference is reduced by 53.3%, and the energy density is increased by 13.14%. In addition, Equivalent circuit model (ECM) and volume of fluid (VOF) model were used to simulate the LIC module, and the numerical results are in good agreement with the experimental data. This study provides a systematic design plan and numerical method for the engineering application of LIC in the field of BTMS.

Effective battery pack cooling by controlling flow patterns with vertical and spiral fins

Battery Thermal Management System (BTMS) is essential for dissipating heat and controlling temperature distribution within the battery pack of an electric vehicle to maintain its optimal operating temperature. This research focuses on the influence of cooling fins in achieving balanced temperature distribution inside the battery pack. Vertical and spiral fins are attached around 21,700 cylindrical cells for this investigation. ANSYS FLUENTsoftwareis employed to conduct the numerical simulations, where a finite volume approach is used to solve the mass conservation, Navier–Stokes, and energy transport equations. The study also uses a set of polynomial functions to calculate the heat generation inside the cells. It assesses the effects of the Reynolds number, fin loop number, and outlet section of BTMS at numerous discharge rates. The findings indicate that the spiral fins significantly impact the thermal performance, reducing Tmax by 21.31 % due to the enhanced flow circulations within the BTMS. A high Reynolds number also positively affects Tmax by reducing the temperature uniformity caused by the shorter time for air-cooling contact with the cell surfaces. More specifically, at a Reynolds number ≥9433, a Z-type BTMS with the spiral fins can maintain the temperature uniformity at a temperature difference of 5 °C. Among the six different BTMSs analysed, a U-type BTMS is reported to have the best performance, reducing Tmax and ΔTmax by 4.11 % and 38.1 %, respectively. The pressure drop in this case is also reduced by 8.46 %, thus lowering the overall power consumption.

Thermal management analysis with different PCMs in Sodium-Ion batteries

The advent of modern technology has led to a significant increase in the utilisation of rechargeable secondary batteries. Despite the sustainability of lithium-ion (Li-ion) batteries, the limited availability of lithium has driven research into alternative energy storage technologies. Sodium-ion (Na-ion) batteries, as a potential alternative to Li-ion batteries, have emerged as a highly promising contender. However, for these batteries to become industrially viable, certain properties such as energy and power density need to be enhanced. To address this issue, batteries have been a focus of research, and battery thermal management systems have been developed. These systems aim to evaluate battery performance, which is strongly influenced by temperature. Effective thermal management ensures that the battery operates within the optimal temperature range. This study models a pouch-type battery and evaluates the effects of phase changing materials (PCM) on battery temperature control. Comparative analysis is conducted using different PCMs to understand their impact. The study analyses the battery's response to specific temperature ranges and assesses how different PCMs affect battery cooling performance. The results provide critical insights for ensuring efficient battery operation. Furthermore, this research supports the broader adoption of Na-ion batteries in industrial applications and contributes to the development of sustainable energy storage systems.

Optimization of Operating Conditions for Battery Thermal Management System

With the rapid increase in the number of vehicles worldwide, we are currently experiencing a scarcity of nonrenewable energy, such as fuel, and the resulting environmental risks associated with vehicle utilization [...]

Study on novel battery thermal management using triply periodic minimal surface porous structures liquid cooling channel

Battery thermal management is a crucial condition for ensuring the safe operation of electric vehicles. The triply periodic minimal surface (TPMS) porous structure boasts high porosity, a large specific surface area, and excellent thermal physical properties. In this study, a novel liquid-cooling channel is designed based on these characteristics. The channel is filled with porous structures and applied in the battery thermal management system (BTMS). Utilizing numerical analysis, compared the cooling performance of liquid-cooling channels filled with different porous structures and investigated the thermal performance of battery modules under diverse factors. The results indicate that the addition of porous structures to the liquid-cooling channel can effectively restrict the maximum temperature of the battery pack and enhance thermal uniformity. Compared to straight tube channel, the Tmax and ΔT of the battery pack with Primitive liquid-cooling structures were reduced by 12.43 % and 8.41 %, respectively. Increasing the volume fraction of the porous structures improves the thermal performance of BTMS, with the best comprehensive performance at a volume fraction of 20 % for the Primitive porous structures. Mass flow rate selection requires attention to the balance between performance and power consumption. Widening the contact angle has the potential to enhance the thermal uniformity of the battery cell, reducing the maximum ΔT of the battery (No.1) from 4.55 °C to 3.46 °C. In addition, the Primitive liquid-cooling structure demonstrates excellent heat dissipation even under extreme temperature conditions, effectively reducing the risk of thermal runaway due to overheating of the battery.

Simulation of Battery Thermal Management System for Large Maritime Electric Ship’s Battery Pack

Simulation of Battery Thermal Management System for Large Maritime Electric Ship’s Battery Pack

Experimental study of a novel guided sequential immersion cooling system for battery thermal management

Immersion cooling exhibits superior cooling performance compared to traditional battery thermal management systems (BTMS). However, a significant challenge of immersion cooling is the spatial variation of temperature within both the coolant and lithium-ion batteries (LIBs). This research proposes a guided sequential immersion cooling (GSIC) BTMS to address this issue. Experimental studies were conducted to evaluate the heat dissipation performance of the GSIC structure under various conditions, including extreme loads. The results indicate that under the static flow immersion cooling (SFIC) scheme, cooling the tabs significantly influences the overall performance. Immersing the tabs can reduce the maximum battery temperature by 10.403 °C, although the spatial variation of temperature persists. Under forced flow immersion cooling (FFIC) conditions, increasing the coolant flow rate dissipates the heat generated by LIBs more effectively. Even at an extreme discharge rate of 5C, the maximum temperature remains below 45 °C. The average temperature reduction at the tabs is greater than the battery body, and with increased flow rates, the temperature difference between the two can be maintained within 1 °C under all conditions. As the flow rate keeps increasing, the average temperature at the tabs gets even lower than the battery body at low loads. This demonstrates that the GSIC BTMS can suppress the temperature rise at the tabs, which is a critical heat risk. Moreover, the temperature uniformity of the LIBs module is improved. As the flow rate increases, the temperature difference within the LIBs module decreases when the discharge rates is between 1C and 5C. Theoretical analysis confirms that increasing flow rates for low loads can suppress temperature rise, albeit with increased power consumption and reduced cooling efficiency. High flow rates are more suitable for high load conditions of the LIBs. These results validate the feasibility of the GSIC BTMS and provide new insights for the development of immersion cooling BTMS.

Advances in solid-state and flexible thermoelectric coolers for battery thermal management systems

Advances in solid-state and flexible thermoelectric coolers for battery thermal management systems

Numerical Investigation of the Thermal Performance of Air-Cooling System for a Lithium-Ion Battery Module Combined with Epoxy Resin Boards

Lithium-ion batteries (LIBs) have the lead as the most used power source for electric vehicles and grid storage systems, and a battery thermal management system (BTMS) can ensure the efficient and safe operation of lithium-ion batteries. Epoxy resin board (ERB) offers a wide range of applications in LIBs due to its significant advantages such as high dielectric strength, electrical insulation, good mechanical strength, and stiffness. This study proposes an air-cooled battery module comprised of sixteen prismatic batteries incorporating an ERB layer between the batteries. To compare the performance of the ERB-based air-cooling system, two other air-cooling structures are also assessed in this study. Three-dimensional numerical models for the three cases are established in this paper, and the heat dissipation processes of the battery module under varying discharge rates (1C, 2C, and 5C) are simulated and analyzed to comprehensively evaluate the performance of the different cooling systems. Comparative simulations reveal that incorporating ERB into the battery assembly significantly reduces battery surface temperatures and promotes temperature uniformity across individual batteries and the entire pack at various discharge rates. Notably, under 5C discharge conditions, the ERB-based thermal management system achieves a maximum battery surface temperature increase of 16 °C and a maximum temperature difference of 8 °C between batteries. Additionally, this paper also analyzes the impact of battery arrangement on air-cooling system performance. Therefore, further optimization of the structural design or the integration of supplementary cooling media might be necessary for such demanding conditions.

An experimental study on lithium-ion electric vehicles battery packs behavior under extreme conditions for prevention of thermal runaway

The need for efficient and dependable lithium-ion battery packs has significantly increased as a result of the progressively rising sales of electric vehicles (EVs). Thermal management is one of the key factors in battery performance and durability. To avoid thermal deterioration, improve safety, and maximize system effectiveness, the battery pack's temperature must be carefully managed. These battery systems' potential for thermal runaway has raised concerns about how safely they can be operated in harsh environments. Environmental considerations, governmental laws, and developments in battery technology are driving the switch from internal combustion engines to electric automobiles. Lithium-ion batteries are sensitive to temperature variations and operating them outside the optimal temperature range can lead to accelerated degradation, reduced capacity, and compromised safety. Key performance indicators used to assess battery thermal management system effectiveness include temperature uniformity, cooling effectiveness, energy usage, and effect on battery life. This paper describes an experimental investigation that looked at how lithium-ion EV battery packs behaved in harsh environments. It also suggests a unique strategy to prevent thermal runaway by using materials like Transformer Oil (TO) and Phase Change Materials (PCM). A specially built experimental setup was created to undertake this inquiry in order to imitate several extreme situations, including high ambient temperatures. A lithium-ion (NMC) battery pack (7S3P) was put through the experimental phase's predicted harsh circumstances to see how it would react thermally. In order to obtain insight into the underlying mechanisms causing thermal runaway, the data acquired were evaluated, and crucial thermal metrics like temperature distribution, heat dissipation, and thermal gradients were studied. The experiment's findings showed that under extreme circumstances, conventional cooling techniques were ineffective in preventing thermal runaway, which resulted in serious safety risks and a reduction in battery performance. The suggested strategy, which incorporates PCM and TO, was then put into practice to fix these flaws and improve battery safety. Due to their ability to self-regulate, they served as components that prevented thermal runaway by limiting the rise in temperature under high-stress situations.

The novel stereoscopic cooling plate designs and performance analysis for battery thermal management systems

This study explores the design and performance of liquid cooling plate-based battery thermal management system for lithium-ion battery packs through numerical simulation. We first assess traditional straight-channel cooling plates with three different placement strategies. The conventional design with bottom-mounted cooling plates demonstrates the most effective thermal management at the same total coolant mass flow rate. This suggests that the influence of reducing coolant flow velocity on the cooling performance outweighs the influence of increasing the heat exchange area under our simulated conditions. Advanced stereoscopic cooling plate structures, referred to as 3DCP-A and 3DCP-B, are then introduced, significantly enhancing battery thermal management performance. To achieve a maximum temperature difference ≤ 5.0 K for the most discharge process, the required mass flow rate of the 3DCP-B decreases by 30.0 g∙s−1 and 10.0 g∙s−1 compared to the conventional bottom-mounted cooling plate and 3DCP-A, respectively, and the pressure drop reduces by 75.9 % and 44.3 %, respectively. The power consumption for the 3DCP-B design is only 6.0 % of that for the traditional design. Finally, the effects of key operating temperatures on the cooling performance of the optimal 3DCP-B design are discussed. The insights obtained in this study provide valuable guidance for developing more efficient and effective pack-level liquid cooling plate-based battery thermal management system, essential for improving the reliability and performance of electric vehicles.

Enhancing Thermal Performance and Cooling Solutions of Phase Change Material in Battery Thermal Management System: A Computational Analysis

ABSTRACTBatteries, particularly lithium‐ion batteries, are sensitive to temperature changes. Battery thermal management systems (BTMS) are essential in various battery‐powered applications, especially electric vehicles (EVs) and portable electronic devices. This study examines the importance of phase change material (PCM) in battery packs using numerical analysis. An examination is conducted on a battery pack consisting of 18 650 battery cells arranged in a 5 × 5 configuration. A comparative analysis is performed to evaluate the thermal efficiency of the battery pack with and without PCM. The study examines the influence of ambient conditions and charging rates on the selection of PCM for battery packs. A hybrid cooling solution utilizing PCM and a water tube has also been investigated against conventional passive PCM‐based BTMS. Additionally, two types of fins, namely circular and spiral fins, are introduced to improve the heat transfer rate. PCM‐based cooling systems are most effective when the ambient temperature is below the melting temperature of the PCM. However, when the ambient temperature exceeds the melting temperature of the PCM, this cooling system outperforms conventional PCM‐based cooling. The maximum temperature is found as 319, 316.9, and 315.3 K using without fin, circular fin and spriral fina, respectively. The spiral fins are found more effective than circular fins under high ambient temperature. In conclusion, The PCM‐with spiral‐fin system demonstrates notable benefits in high‐temperature environments.

Investigation on Cooling Performance of Composite PCM and Graphite Fin for Battery Thermal Management System of Electric Vehicles

ABSTRACTModern electric vehicle (EV) batteries need phase change materials (PCM) that are capable of efficient battery cooling. In this work, a composite PCM is prepared by mixing Fe3O4 nanoparticles (1 wt.%) in paraffin, and the effects of these nanoparticles on the enthalpy and melting point of PCM are studied. It is found that the Fe3O4 nanoparticle additives reduce the onset of melting from 61.46°C to 57.03°C. The composite PCM is used for the cooling of a battery module of 6 substitute‐18 650 batteries, and the cooling performance is experimentally and numerically investigated. The hybrid battery thermal management system (BTMS) utilizing composite paraffin demonstrates a significant reduction of 11.2°C in lithium‐ion battery (LIB) temperature compared with natural convection cooling at a heat generation rate of 2W. The numerical results in this study are in good agreement with the experimental temperature values, with a modest mean absolute error of 1.35°C detected between experimentally obtained and simulated battery temperature values. In order to deal with the low thermal conductivity of liquid PCM after PCM melting, a numerical investigation is conducted to study the effect of a graphite fin on the battery temperature. The use of a fin in hybrid BTMS considerably reduces the temperature of LIBs and temperature difference in the module. The numerical simulations capture the behavior of the phase change phenomenon, showing the evolution of liquid PCM under constant heating. This work presents the dynamic melting patterns of PCM along the length of LIB with and without a fin, which is useful for the effective design of BTMS.

Passive battery thermal management and thermal safety protection based on hydrated salt composite phase change materials

Lithium-ion batteries (LIBs) are progressing towards higher energy densities, extended lifespans, and improved safety. However, battery thermal management systems are facing increased demand owing to high-rate charging and discharging, dynamic operating conditions, and heightened thermal safety concerns. Therefore, this paper proposes a novel composite phase change material (CPCM) comprising Na2SO4-10H2O as the core phase change material (PCM) and expanded graphite as the thermal conductivity enhancer. The CPCM offers high latent heat, superior thermal conductivity, and a two-stage temperature control function for battery thermal management and safety. The optimal mass CPCM ratio, determined through comprehensive characterization and thermal property tests, resulted in a melting point of 29.05°C, latent heat of 183.7 J.g−1, and high thermal conductivity of 3.926 W.m−1.K−1. During normal LIB operations, the CPCM efficiently absorbs and transfers heat, reducing the peak LIB temperature from 66 to 34°C at 15°C ambient temperature during a 3.7C high-rate discharge. Under dynamic conditions, the peak temperatures across the three cycles were consistently controlled at 36.7, 36.4, and 35.8°C, respectively. In a thermal runaway state, the thermochemical heat storage of hydrated salt dehydration effectively slowed LIB temperature increase, delaying the time to reach 130°C by 187 s. Suppression of the temperature rise outside the CPCM, combined with an extended dehydration plateau of up to 320 s, prevented the occurrence and propagation of thermal runaway in the battery.

Research Progress of Microchannel Liquid Cooling Technology in the Application of Thermal Management of Prismatic Lithium Batteries (Withdrawn)

Lithium-ion batteries have significant advantages such as high energy density, long cycle life and low self-discharge rate. Therefore, they are ideal for energy storage in electric vehicles. However, lithium-ion batteries are very sensitive to temperature, which affects the battery's cycle life, efficiency, reliability and safety. During the charging and discharging process, a large amount of heat is generated inside the battery due to the electrochemical reaction and resistance, causing the battery temperature to rise. When the temperature gets too high, thermal runaway, electrolyte fire and explosions may occur. As battery energy density increases, the demand for efficient thermal management continues to increase, and a compact and efficient battery thermal management system is essential. This paper introduces the development status of different thermal management technologies, reviews the application of microchannel liquid-cooling technology in the thermal management of prismatic lithium batteries, discusses the current research direction and status of microchannel technology, and finally looks forward to the future research and development direction of microchannel technology.

A numerical study on a hybrid battery thermal management system based on PCM and wavy microchannel liquid cooling

With the emerging development of electrical vehicle, the efficient thermal management of the lithium-ion battery is becoming a critical point for its wide application and normal operating. Hence, based on the advantages of liquid cooling and PCM, a novel hybrid cooling system using PCM coupled with wavy microchannel cooling plate (PCM-WMCP) was proposed in this paper, and a numerical study was carried out to investigate its performance. It's found the hybrid cooling system with PCM and microchannel cooling plate showed much lower battery temperature than individual PCM and air cooling systems, moreover, among the hybrid cooling systems, the novel PCM-WMCP exhibited 2 K lower maximum battery temperature than PCM-SMCP (straight microchannel cooling plate) type at 1C, and increased potential in utilizing PCM for heat dissipation. The PCM was further modified to composite PCM (CPCM) by adding expanded graphite, which was found to realize a further lower maximum battery temperature and more uniform battery temperature field, with graphite mass fraction of 10 %. Besides, facing thermal runaway, the CPCM-WMCP cooling system showed a better temperature control ability compared to CPCM-SMCP, with temperature suppressed to below 318 K, and the maximum temperature difference at about 1.6 K.