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• The heat generation model for cylindrical Li-ion battery was built. • A liquid immersion cooling battery pack containing 60 batteries were established. • At 2C discharge rate, 0.5 L/min flow rate was recommended. • The battery pack can address localized high-rate discharge events (4.5C or 6.5C). • Liquid immersion cooling BTMSs have great heat dissipation performance. With the increasingly severe challenges of the thermal management of battery packs for electric vehicles, the liquid immersion cooling technology has gradually attracted more attention due to its superior characteristics such as high heat dissipation efficiency, well temperature uniformity and low risk of thermal runaway. To investigate the heat transfer characteristics of the liquid immersion cooling BTMSs, the 3D model of the 60-cell immersion cooling battery pack was established, and a well-established heat generation model that leveraged parameters derived from theoretical analysis and experiments was incorporated into the 3D simulation to analyze the thermal characteristics of battery pack. The simulation results showed that under the discharging rate of 2C, even with the lowest coolant flow rate in this work (0.2 L/min), no localized abnormal overheating within the battery pack was observed, and the highest temperature was 34.22 °C. The temperature uniformity within the battery pack improved with the increase of the coolant flow rate. It was recommended to maintain a flow rate above 0.5 L/min to ensure a temperature difference below 5 °C. The experimental apparatus of the immersion cooling battery pack was also developed to explore the heat dissipation and temperature uniformity at 2C discharge rate. The simulation results were in well agreement with the experimental results, with the deviation less than 0.43 °C when the flow rate exceeded 0.6 L/min. The effect of the localized high-rate discharge events (4.5C and 6.5C) at different battery pack locations on temperature distribution and uniformity was further discussed based on the verified 3D model. The results suggested that liquid immersion cooling systems offered promising potential for achieving both efficient heat dissipation and preventing thermal runaway in battery packs. [ABSTRACT FROM AUTHOR]

This paper proposes a new novel battery cooling system for hydrogen fueled HEVs that achieves more efficient cooling and driving, which increases vehicle driving range and enhances vehicle safety by maintaining the batteries at optimum operating conditions. The proposed system offers a novel use of the vehicle fuel and a novel cooling plate design. The cooling plate design is optimized in terms of battery's temperature uniformity and battery's maximum temperature. The optimum performance of the design is then investigated through a 600 s high intensity discharging and charging cycle of 4C. The results show that when hydrogen is at a temperature of 10 °C and has an inlet velocity of 0.01 m/s, the maximum temperature is maintained at lower than 30.5 °C. The lowest difference through the battery obtained by the proposed system is less than 7 °C. The performance of the proposed system is compared with the performance of liquid, air and evaporative cooling based systems. The comparison shows that the proposed system is able to perform better than liquid, air and evaporative cooling based cooling systems. The performance of the proposed cooling system demonstrates the advantage of integrating the hybrid vehicle fuel system with the battery cooling system. [ABSTRACT FROM AUTHOR]

This paper presents the modeling of a 50 A h battery pack composed of 56 cells, taking into account real battery performance conditions imposed by the BMS control. The modeling procedure starts with a detailed analysis of experimental charge and discharge SOC tests. Results from these tests are used to obtain the battery model parameters at a realistic performance range (20–80% SOC). The model topology aims to better describe the finite charge contained in a battery pack. The model has been validated at three different SOC values in order to verify the model response at real battery pack operation conditions. The validation tests show that the battery pack model is able to simulate the real battery response with excellent accuracy in the range tested. The proposed modeling procedure is fully applicable to any Li-ion battery pack, regardless of the number of series or parallel cells or its rated capacity. [ABSTRACT FROM AUTHOR]

• A 35kWh battery pack with a novel hybrid thermal management system is prototyped. • Phase change material is innovatively integrated with cooling plate. • The battery thermal management at the battery pack level and module level is studied. • Both cooling and thermal insulation performances are investigated. • Desirable control strategies are obtained for battery pack under 0.5C to 1.5C discharge rates. Controlling the temperature of a battery pack within an optimal range and ensuring uniform temperature distribution are the key to improving battery life. With the elevating energy density of batteries, more efficient and energy-saving thermal management system is urgently required for improving electric vehicle (EV) performance in terms of safety and long-term durability. In this work, a novel hybrid thermal management system towards a high-voltage battery pack for EVs is developed. Both passive and active components are integrated into the cooling plate to provide a synergistic function. A 35kWh battery pack incorporated with electrical, mechanical and thermal management components was designed, manufactured and integrated. As the core hardware, a pack-level cooling plate set was innovatively designed by integrating with phase change material (PCM). The results show that the combined passive and active cooling strategy ensured a desirable working temperature below 40˚C and a uniform heat distribution across the entire pack at discharging rates ranging from 0.5C to 1.5C under customized control strategies. Moreover, the cycling performance of air cooling and hybrid cooling, as well as the thermal insulation performance at both battery module level and pack level are compared, demonstrating the superior thermal management capability of the hybrid solution. [ABSTRACT FROM AUTHOR]

Lithium-ion battery systems are becoming a major component in numerous applications. The thermal behaviour of cells should be monitored for many reasons. In this paper, the investigation of the energy balance for lithium-ion battery system is described. The electrothermal model allows to describe heat generation and heat dissipation processes in all components of a battery pack (BP). Moreover, this model can be easily adapted for bigger, modular battery systems, since the primitive in the proposed model is a single cell. A method to determine the energy balance through experimental investigations and to validate the model is also proposed. Four types of BPs with sixteen cylindrical 18650 lithium-ion cells were tested. The influence of both busbar material and the presence of heatsinks on the BP thermal conditions was investigated. The results show that the heat accumulated in cells can be decreased by 20% and the cell temperature lowered by 8 °C if additional elements are used in a BP. [ABSTRACT FROM AUTHOR]