Search

The temperature has a significant effect on the lifespan and the safety of the batteries which are one of the core components of electric vehicles. A well-designed battery thermal management system is required to adjust the temperature of the batteries within an appropriate range for thermal safety, and further minimize the energy consumption for energy savings. However, these two goals form a tradeoff. Typically, increased energy consumption for cooling results in safer batteries thermally. To examine this tradeoff, firstly, a linear electro-thermal model is built to evaluate the thermal dynamics of the operating battery-cooling module. The linear model accounts for the heat generation based on internal resistance, and the heat transfer based on a resistance–capacitance model. Such linear model reduces the computation of the model simulation to dynamically catch up with the change of temperatures and to implement control strategies on the cooling system in a short time. Based on this model, a model predictive control (MPC) framework is proposed to design thermal control methods, which considers both thermal safety and energy saving. The weight of these two goals can be adjusted to explore the tradeoff between them. Finally, we investigate the performance of the MPC framework by applying the Urban Dynamometer Driving Schedule (UDDS) to the battery module. The simulation results show that the electro-thermal model is effective for battery thermal dynamics evaluation. Additionally, the tradeoff between the two goals is demonstrated by the simulation. • A fast temperature prediction and closed-loop thermal control framework is proposed. • An electro-thermal model of an active-liquid-cooling battery module is developed. • A thermal prevention control strategy is proposed. [ABSTRACT FROM AUTHOR]

This paper describes a set of experimental tests carried out to better understand the thermal behavior of Lithium-ion batteries under load and the capability of various cooling fluids in maintaining the working conditions within a safe range for the cells. Despite several theoretical models are available in the literature, very few experimental data are reported. Different types of cells have been analyzed. The generation of hot spots has sometimes been registered, their occurrence being independent of cell geometry and size; instead, the battery's history and age, appeared the main factors in determining the onset of hot spots on the surface of the cell. Two experimental rigs have been set up to test the capability of different cooling fluids in removing the surplus heat generated in a Li-ion battery module, where the cells of interest have been replaced with electrically heated elements with the same thermal characteristics of the cells. It was thus possible to safely investigate "extreme" operating conditions, where the occurrence of a thermal runaway is possible. Among the tested fluids, air was unable to adequately limit the surface temperature increase, while a perfluorinated polyether, allowed to work within the optimal temperature range, even under severe operating conditions. • The thermal behavior of different types of Li-ion batteries has been experimentally investigated. • The cells have been tested under both ordinary and severe operating conditions. • Dangerous operating conditions of the batteries have been identified. • A reliable and dedicated experimental facility has been set up. • The cooling efficiency of a range of thermal fluids has been evaluated. [ABSTRACT FROM AUTHOR]

• Structural theory is adopted to design the bifurcating channels of the cold plate. • Effects of structural parameters and flow rate on cooling performance are studied. • Optimization of main channel width has the greatest effect on reducing pressure drop. For rectangular Li-ion batteries, this paper optimized the heat dissipation of the cold plate embedded with leaf-like network according to the structural theory. Not only the distributed network layer was established, but also the collection network layer was designed to mitigate the inherent temperature gradient problem of the conventional single channel. The effects on the split point of symmetrical/asymmetrical bifurcation, the width ratio of symmetrical bifurcation, the inlet mass flow rate, the number of feed-out channels and the width of main channel on the thermal performance of cooling plate were numerically simulated. The results demonstrated that the heat dissipation was better when the split point is near the limit position of the outer channel. Compared with the offset bifurcation network, the symmetric bifurcation network can achieve better heat transfer characteristics, but its pressure drop was slightly higher than that of offset bifurcation network. The increase of width ratio and inlet mass flow can meet both maximum temperature and temperature uniformity objectives, but at the expense of pressure drop. Compared with the single feed-out channel, the double feed-out channels can meet both the thermal performance and the pressure drop requirements. As the width of the main channel (D 1) was elevated, pressure drop greatly declined on the basis of heat transfer. The simulation results can provide a reference for the design of cold plate embedded fractal-like network based on battery thermal management systems. [ABSTRACT FROM AUTHOR]

Highlights • A novel cooling strategy based on the air distribution pipe is proposed for the cylindrical Lithium-ion battery module. • The 3D CFD model of the battery module based on the air distribution pipe is constructed. • The temperature of battery near the positive pole is higher than that near the negative pole during discharging. • The maximum temperature of battery module can be effectively reduced via increasing inlet pressure. • The maximum temperature of battery module declines when the diameter and number of rows for orifice become large. Abstract For a typical air cooling thermal management system, the inlet and outlet of air flow on both sides of the battery module would increase the temperature difference. In here, a novel cooling strategy based on air distribution pipes is proposed for the cylindrical Lithium-ion battery module. The three-dimensional computational fluid dynamics model of battery module is constructed and validated by the experimental tests. The thermal behavior of battery module and the flow field of air have been explored using numerical simulations at different discharge rates, and then the effects of orifice parameters, inlet pressure and discharge rate on the performance of air cooling strategy have been analyzed. The results show that the maximum temperature of the battery module can be effectively reduced by the increase of inlet pressure resulting in a significant rise of power consumption. Meanwhile, it declines when the diameter and number of rows of the orifice increase, following a minor rise in power consumption. When the inlet pressure is 100 Pa, the diameter of the orifice is 1.5 mm, the number of rows of the orifice is 5 and the discharge rate is 3C, the maximum temperature of battery module decreases from 325.9 K to 305.7 K in comparison to that under none air cooling condition. In addition, the maximum temperature difference of battery module is within 3 K. When the battery module discharge at the current rate of 4C and 5C, the maximum temperature of battery module maintains within 313.15 K, but the temperature difference slightly exceeds the optimal range at 5C discharge when the inlet pressure is 200 Pa, the diameter of the orifice is 1.5 mm and the number of rows of the orifice is 5. Moreover, it is an efficient and a practical cooling strategy with no need to modify the arrangement of the battery module. [ABSTRACT FROM AUTHOR]

Heat generation and accumulation during working schemes of the lithium-ion battery (LIB) are the critical safety issues in hybrid electric vehicles or electric vehicles. Appropriate battery thermal management is necessary for ensuring the safety and continuous power supply of rechargeable LIB modules. In this study, thirty cylinder 18650-type cells were fabricated a 6S5P battery module with a 2-mm spacing between cells to evaluate exothermic trajectories. The modules, equipped with a forced-air cooling system, were charged at 1 C-rate and discharged at 1, 1.5, and 2 C-rates for three cycles in each test; thermocouples were connected to the cells to track the variances in temperature and voltage. The efficiency of the developed forced-air cooling system was estimated to be 73.0% in case 1 with the 1 C discharge rate, and the temperature difference (TD) was less than 5.0 °C. The maximum temperature (Tmax) of this case was maintained below 45.0 °C showing uniform heat distribution. Moreover, extreme heat accumulation developed inside the module and damaged the adjacent LIBs during fast 2 C discharge test. Our TD testing showed that a forced-air cooling system in the LIB module provides effective heat dispersion under normal discharge conditions. [ABSTRACT FROM AUTHOR]

Abstract In this paper, the thermal management based on phase change slurry (PCS) and mini channel cooling plate for the lithium-ion pouch battery module was proposed. The three-dimensional thermal model was established and the optimum structure of the cooling plate with mini channel was designed with the orthogonal matrix experimental method to balance the cooling performance and energy consumption. The simulation results showed that the cooling performance of PCS consisting of 20% n-octadecane microcapsules and 80% water was better than that of pure water, glycol solution and mineral oil, when the mass flow rate was less than 3 × 10−4 kg s−1. For different concentrations of PCS, if the mass flow rate exceeded the critical value, its cooling performance was worse than that of pure water. When the cooling target for battery maximum temperature was higher than 309 K, the PCS cooling with appropriate microcapsule concentration had the edge over in energy consumption compared with water cooling. At last, the dimensionless empirical formula was obtained to predict the effect of the PCS's physical parameters and flow characteristics on the heat transfer and cooling performance. The simulation results will be useful for the design of PCS based battery thermal management systems. Highlights • Battery thermal management based on the PCS and mini channel was proposed. • The cooling plate was designed to balance the cooling effect and energy consumption. • The management cooled battery effectively and performed better than water cooling. • The optimal mass flow rate for different concentrations of PCS was determined. • The dimensionless empirical formulas were obtained. [ABSTRACT FROM AUTHOR]

In order to investigate a simple and efficient liquid cooling method for the rectangular Li-ion power batteries used in electric vehicles, the cold plate with serpentine-channel configuration shaped like U-tube is established. Subsequently, the effect of cooling channel number, the layout of channels and inlet temperature of coolant on cooling performance of battery thermal management system are analyzed. The numerical simulation results demonstrate that the layout of channels in length flowing-direction with 5-channels has the most efficient cooling performance. This design can reduce the maximum temperature by 26 °C compared with the 2-channels along width flowing direction. And the maximum temperature of cooling system rises with the increase of inlet temperature of the coolant. However, there exists an upper limit on the number of channels and the inlet temperature with the consideration of efficiency and safety of cooling system. The above results will be helpful to design cold plate for thermal management system of Li-ion power batteries. [ABSTRACT FROM AUTHOR]

• A novel design of an efficient air-cooling system for improving the performance of lithium-ion batteries. • It is revealed that the average Nusselt numbers (Nu) are an increasing function of Reynolds numbers (Re). • The cells, which receive fresh cold external flow cause a substantial reduction in the cell surface temperature. • Increasing Re also reduces the cooling pack outlet temperature, which leads to the improved life of the batteries. Modern society depends on energy storage systems like Lithium-ion (Li-ion) batteries. Li-ion battery cells are delicate to changes in temperature. Extreme environmental conditions affect their life cycle and performance. Therefore, effective cell temperature management is a must for secure and dependable battery operation. Additionally, the high production costs of electric cars must be countered by the adaptability of the battery pack design for modern electric vehicles. As the chemical reactions generate more heat and raise the battery's temperature, it may cause the battery to explode and cause fires in the workplace. To address this issue, the present work attempts to numerically study a novel design of an efficient air-cooling system for improving the performance of lithium-ion batteries by reducing the operational temperatures under a different coolant flow rate. The main output of the presented study is the analysis of a novel design of an efficient air-cooling system for lithium-ion batteries. The study aims to reduce the operational temperatures of the batteries under different coolant flow rates to improve their performance and service life. The numerical simulations are carried out using a finite volume-based computing tool with the K-epsilon (k-ε) turbulence model. The analysis is performed for various pertinent parametric ranges, including the spacing between the batteries, Reynolds numbers, and average Nusselt numbers. The results indicate that increasing air inlet velocity (Re) substantially reduces the average air temperature of the cooling pack and temperature difference (ΔT) of the battery cells, and the cooling pack's average heat transfer rate (Nu) increases monotonically as the Re increases. [ABSTRACT FROM AUTHOR]

• The quantity of heat generation that induce TR in lithium-ion batteries is lower than in other overheating strategies. • The trigger time of thermal runaway decreases with the increasing current density. • The series tab connection will accelerate the thermal runaway of the adjacent battery. • The parallel tab connection will induce thermal runaway propagation to all parallel-connected batteries. Thermal runaway (TR) of lithium-ion batteries is the main safety obstacle to the further development of electric vehicles (EVs) and electric energy storage systems (EESSs). Understanding the mechanism of TR propagation is one of the primary ways to improve the thermal safety of the lithium-ion battery. In this paper, an electro-thermal model coupled with the lumped thermal runaway model is applied to investigate the TR behaviors induced by tab overheating and the TR propagation in a battery module with different tab connection methods. The electro-thermal model is used to calculate the heat generation at tabs and the cell body during the normal charge/discharge process, and the lumped thermal runaway model is applied to calculate the TR behavior and TR propagation in the battery module. The results exhibit that the TR behavior and TR propagation are influenced by different aspects (C-rates, insulator, and tab connection modes) in the battery module. The largest quantity of heat generation is at 3C-rate, about 0.98 kJ, because of the heat accumulation in the battery. Besides, the quantity of heat generation that induce TR in lithium-ion batteries in this paper is lower than that from the reference, which means that tab overheating is more dangerous than other heating strategies for triggering the thermal runaway of batteries. The trigger time of TR decreases with the increasing C-rate and the tab connection modes mitigate the TR propagation in the battery module at a low C-rate because of the increasing heat dissipation rate, while the TR propagation is accelerated in the battery module at a high C-rate. At low C-rate conditions, the parallel tab connection exhibits a more significant effect on mitigating the TR behavior, and the effect of mitigation decreases with the increasing C-rate. At high C-rate conditions, the series tab connection accelerates the TR propagation to the adjacent battery, while the parallel tab connection speeds up the TR propagation of all the connected batteries. This work is important for understanding the TR propagation mechanism and improving the thermal safety of pouch-type lithium-ion batteries in EVs. [ABSTRACT FROM AUTHOR]

Summary: With the depletion of fossil fuels and the aggravation of environmental pollution, the research and development speed of electric vehicles has been accelerating, and the thermal management of battery pack has become increasingly important. This paper selects the electric vehicle battery pack with natural air cooling as the study subject, conducts simulation analysis of the heat dissipation performance of battery packs with and without vents. Then this paper researches on the influence of internal flow field and external flow field. Field synergy principle is used to analyze the effect of velocity field and temperature field amplitude. The results show the following: it is found that the maximum temperature rise and the internal maximum temperature difference of the battery pack with vents are reduced by about 23.1% and 19.9%, raising speed value can improve the heat dissipation performance, and raising temperature value can decrease the heat dissipation performance. Reasonable design of the vents can make the inner and outer flow field work synergistically to achieve the best cooling effect. Then the reference basis for the air cooling heat dissipation performance analysis of electric vehicle, battery pack structure arrangement, and air‐inlet and air‐outlet pattern choosing are offered. [ABSTRACT FROM AUTHOR]

Summary: Some potential safety risks for lithium ion battery such as overheating, combustion, and explosion occurred in practical application may cause accidents of electric vehicles. Phase change material (PCM)‐based thermal management system was demonstrated as a feasible approach. However, the batteries have to endure various environment and climate, which would not work normally under cold area. Especially when the surrounding temperature falls to below 10°C, which can bring about the energy and power of Li‐ion batteries rapidly reducing. In this study, a coupling heating strategy of the PCM‐based batteries module with 2 heat sheets at low temperature was proposed for batteries module and cannot only balance the temperature among different batteries in the module but also ensure to pre‐heat the batteries module at low temperature. The experiment displayed that 7% of EG in paraffin‐based composite PCMs was the best proportion for batteries module, considering both fluidity and thermal conductivity factors. In addition, the temperature difference of PCM‐based batteries module was 2.82°C, while that of the air‐based one was 14.49°C, which was 5 times more than former, exhibiting an excellent performance in balancing temperature uniformly, and was beneficial for prolonging the lifespan of batteries. The coupling heating strategy‐based PCM with heat sheets provided as an extremely promising technology for lithium batteries module at low temperature. [ABSTRACT FROM AUTHOR]

Lithium-ion (Li-ion) battery charging is a crucial issue in energy management of electric vehicles. Developing suitable charging patterns, while taking into account of various contradictory objectives and constraints is a key but challenging topic in battery management. This paper develops a model based strategy that optimizes the charging patterns while considers various key parameters such as the charging speed, energy conversion efficiency as well as temperature variations. To achieve this, a battery model coupling both the electric and thermal characteristics is first introduced. Three key but conflicting objectives, including the charging time, energy loss and temperature rise especially for internal temperature, are formulated. Then, multi-objective biogeography-based optimization (M-BBO) approaches are employed to search the optimal charging patterns and to balance various objectives with different combinations. Optimization results of four M-BBO approaches are compared, and the Pareto fronts for battery charging with various dual-objectives and triple-objectives are analysed in detail. Experimental results confirm that the developed strategy can offer feasible charging patterns and achieve a desirable trade-off among charging speed, energy conversion efficiency and temperature variations. The Pareto fronts obtained by this strategy can be adopted as references to adjust charging pattern to further satisfy various requirements in different charging applications. [ABSTRACT FROM AUTHOR]

Thermal management is a crucial strategy that needs to be carefully considered for lithium-ion batteries under extreme operating conditions. One promising approach is the use of phase change material (PCM), which can bring benefits such as passively thermal buffering and extending lifespan. In this paper, a paraffin/expanded graphite (EG) composites based battery module (PCM module), as well as the two dimensional thermal model is proposed. The effects of different EG mass fractions associated with different phase change enthalpy and thermal conductivity are investigated firstly under high-rate discharge condition. The results show that an optimal mass fraction of EG is needed to achieve the best thermal performance and the EG mass fraction of 15–20% is recommended to be used for battery thermal management. In order to further improve the overall performance, we also design a novel pyrolytic graphite sheets (PGS)-enhanced paraffin/EG composites based battery module (PCM/PGS module). EG with porous structure can create the primary thermal conductive network for PCM to increase the heat absorption rate. PGS forms the secondary thermal conductive network for the module to improve the whole thermal homogeneity. As a result, the as-designed PCM/PGS module presents much better heat dissipation performance and temperature uniformity compared with the PCM module during discharge–charge cycles. Also, the introduction of PGS is beneficial for thermal fluctuations and energy saving, for instance, the thermal performance of PCM/PGS module with a convective heat transfer coefficient of 50 W m −2 K −1 is comparable to PCM module with 200 W m −2 K −1 . In the case of failure mode, to achieve the prevention of thermal runaway propagation, the spacing between cells for PCM module is up to 14 mm. However, the use of PGS lowers the spacing (i.e. less composite PCM consumption) by a decreasing rate of ∼71.4% in comparison with PCM module. [ABSTRACT FROM AUTHOR]

To achieve safe, long lifetime, and high-performance lithium-ion batteries, a battery thermal management system (BTMS) is indispensable. This is especially required for enabling fast charging-discharging and in aggressive operating conditions. In this research, a new type of battery cooling system based on thermal silica plates has been designed for prismatic lithium-ion batteries. Experimental and simulations are combined to investigate the cooling capability of the BTMS associated to different number of cooling channels, flow rates, and flow directions while at different discharge C-rates. Results show that the maximum temperature reached within the battery decreases as the amount of thermal silica plates and liquid channels increases. The flow direction had no significant influence on the cooling capability. While the performance obviously improves with the increase in inlet flow rate, after a certain threshold, the gain reduces strongly so that it does not anymore justify the higher energy cost. Discharged at 3 C-rate, an inlet flow rate of 0.1 m/s was sufficient to efficiently cool down the system; discharged at 5 C-rate, the optimum inlet flow rate was 0.25 m/s. Simulations could accurately reproduce experimental results, allowing for an efficient design of the liquid-cooled BTMS. [ABSTRACT FROM AUTHOR]

Lithium-ion batteries are commonly used in hybrid electric and full electric vehicles (HEV and EV). In HEV, thermal management is a strict requirement to control the batteries temperature within an optimal range in order to enhance performance, safety, reduce cost, and prolong the batteries lifetime. The optimum design of a thermal management system depends on the thermo-electrochemical behavior of the batteries, operating conditions, and weight and volume constraints. The aim of this study is to investigate the effects of various operating and design parameters on the thermal performance of a battery module consisted of six building block cells. An electrochemical-thermal model coupled to conjugate heat transfer and fluid dynamics simulations is used to assess the effectiveness of two indirect liquid thermal management approaches under the FUDC driving cycle. In this study, a novel pseudo 3D electrochemical-thermal model of the battery is used. It is found that the cooling plate thickness has a significant effect on the maximum and gradient of temperature in the module. Increasing the Reynolds number decreases the average temperature but at the expense of temperature uniformity. The results show that double channel cooling system has a lower maximum temperature and more uniform temperature distribution compared to a single channel cooling system. [ABSTRACT FROM AUTHOR]

• A novel encapsulated inorganic phase change material (EIPCM) is synthesized. • EIPCM shows good phase change properties and thermal stability. • EIPCM exhibits good battery thermal management effect on the battery module. • EIPCM delays the battery thermal runaway and inhibits the heat propagation. • The nonflammable EIPCM protects batteries from heavy fire risks and hazards. Although widely used in the thermal management of lithium-ion batteries, organic phase change material (PCM) with flammability has been reported to aggravate the fire risk and heat hazards of battery thermal runaway (TR). To reduce the fire risk of PCM during battery TR, an encapsulated inorganic PCM (EIPCM) was synthesized by a nano-encapsulation method of interfacial polymerization in this study. Na 2 HPO 4 ·12H 2 O was used as the inorganic core material and silica was adopted as the encapsulated matrix to reduce the inherent defects. The synthesized EIPCM was characterized by a series of tests, demonstrating good phase change properties and thermal stability. The melting temperature of the EIPCM was measured as 51 °C associated with the latent heat of 111.69 kJ/kg. The thermal management effects of EIPCM were further investigated on battery modules at various discharge rates. The results show that EIPCM exhibited good cooling performance, leading to a 23.7% reduction of the peak battery temperature from 86.6 °C to 66.1 °C at a high discharge rate of 3C, and the temperature difference was kept within 3 °C. The TR behavior of batteries with IPCM was further explored, and the results indicate that EIPCM could delay the occurrence of TR by 495 s and decrease the peak surface temperature of the battery by 194 °C. With the nonflammable EIPCM, the fire of TR showed rapid extinction, protecting the batteries from heavier fire hazards. It is also found that EIPCM could inhibit the heat propagation of TR. The prepared EIPCM in this work with good thermal management effects and TR suppression performance has great prospects in practical battery applications, energy storage and other fields. [ABSTRACT FROM AUTHOR]

In this paper, techniques to improve cooling and temperature uniformity in a simple battery pack are examined. Four battery pack configurations are developed. In the first configuration, an inlet plenum is added to a simple battery pack. In the second configuration, jet inlets are incorporated along with the inlet plenum, and in the third configuration, multiple vortex generators are added in addition to the inlet plenum. Finally, in the fourth configuration, an inlet plenum, jet inlets, and multiple vortex generators are incorporated into the battery pack. The results conclude that by adding inlet plenum, multiple vortex generators, and jet inlets in the same configuration, significant improvements are observed. The results also show that the maximum temperature of the battery pack is reduced by ∼5%, and the temperature difference between the maximum temperature and the minimum temperature exhibited by the battery pack is reduced by 21.5%. Moreover, there is a ∼16% improvement in the temperature uniformity of a single cell. [ABSTRACT FROM AUTHOR]

Conventional cooling approaches that target either a singular tab or outer surface of common format cylindrical lithium-ion battery cells suffer from a high cell thermal resistance. Under an aggressive duty cycle, this resistance can result in the formation of large in-cell temperature gradients and high hot spot temperatures, which are known to accelerate ageing and further reduce performance. In this paper, a novel approach to internal thermal management of cylindrical battery cells to lower the thermal resistance for heat transport through the inside of the cell is investigated. The effectiveness of the proposed method is analysed for two common cylindrical formats when subject to highly aggressive electrical loading conditions representative of a high performance electric vehicle (EV) and hybrid electric vehicle (HEV). A mathematical model that captures the dominant thermal properties of the cylindrical cell is created and validated using experimental data. Results from the extensive simulation study indicate that the internal cooling strategy can reduce the cell thermal resistance by up to 67.8 ± 1.4% relative to single tab cooling, and can emulate the performance of a more complex pack-level double tab cooling approach whilst targeting cooling at a single tab. [ABSTRACT FROM AUTHOR]

To curb the greenhouse gas (GHG) and carbon emission in line with the Paris climate agreement, the road transportation needs to be electrified. The predicted electrification of the road transport can substantially reduce the GHG emission. The fundamental component in electric vehicles (EVs) is the power battery, in which its performance is affected by temperature. To improve the cooling performance and enhance temperature uniformity in the battery stack, a battery thermal management system (BTMS) comprising heatsinks with fluid channels and multi-phase change materials (PCMs) was investigated in this paper. The module consists of eight prismatic cells with nine fluid passages and PCMs attached at each side of the cell. The heatsink containing PCMs is separated into three equal portions, each is filled with different PCMs. The cooling effectiveness and temperature uniformity of the BTMS were carefully explored based on compactness of the battery stack and cooling fluids. The results indicate that increasing the PCMs thickness supressed the temperature rise by more than 2.85 K and provide better temperature uniformity compared to increasing the fluid channel width for the same volume of heatsink to volume of the battery unit ratio. Liquid cooling is more effective than air cooling in mitigating temperature especially at high ambient temperature. Choosing an appropriate ratio of volume of cooling channel to battery unit is particularly essential and can minimize operation cost. [ABSTRACT FROM AUTHOR]

• The positive tab shows an extreme temperature rise during charge/discharge process. • Heat generation of positive tab for charge is higher than that in discharge. • Ohmic heat generation cause extreme high temperature rise in fast charge process. • Extreme temperature rise can only be controlled by high heat transfer coefficient. Thermal safety is one of the primary requirements for electric vehicles (EVs). Overheating by an external or internal heat source will induce the onset of thermal runaway. An overheating risk caused by tabs of pouch-type lithium-ion batteries was reported and the relevant heat rejection strategies were investigated in this paper. The positive tab showed a much higher temperature rise than that in the body and the negative tab of pouch-type lithium-ion batteries. The temperature reached 70.4 °C in the beginning 100 s with a charge rate of 2 C-rate, showing a fast temperature response. Besides, the largest temperature difference between the charge and discharge process was about 20.2 °C (2 C-rate), which indicates that the positive tab in the charging process is more dangerous than that in discharging process. Moreover, an electro-thermal model was applied to investigate the potential risk of tabs in the pouch-type lithium-ion battery. An extreme temperature rise (∼ 350 °C) in the positive tab showed a potential thermal risk in a high charging rate (6C). And the temperature at the tab can only be controlled under a relatively high heat transfer coefficient (higher than 100 W·m−2·K−1). This work is meaningful for the development of a thermal management strategy in a battery pack with fast charging technologies. [ABSTRACT FROM AUTHOR]

The exposure of electric vehicle batteries to rapid charging and discharging profiles, particularly under uncertainty in the drive schedules, requires effective strategies to forecast and avoid thermal excursions during operation. In this work, we present a light gradient boosting-based machine learning model to create probabilistic forecasts of the discharge current over a forecast horizon in real time. A surrogate of a physics-based computational model provides the functional relationship for the battery temperature, using which a stochastic model-predictive control strategy is developed to derive the optimal cooling schedule based on the probabilistic forecast. The effectiveness of the stochastic model-predictive control approach is assessed on the US06 driving cycle, in comparison to a constant coolant flow and persistence forecast-based control. It is shown that the total number of temperature excursion instances using the stochastic model-predictive control is reduced by about 69% compared to the constant coolant flow case and by over 51% compared to persistence-forecast-based control. Further, the total coolant usage is reduced by about 73% compared to persistence forecast-based control. The stochastic model-predictive control approach provides more flexibility by allowing a wider range of control and battery pack design parameters to obtain optimal performance with minimum coolant use. • Presents model-predictive thermal control of LIBs under drive cycle uncertainty. • Probabilistic forecast of discharge current obtained using machine learning model. • Uses physics-based computational model to derive optimal cooling schedule. • Stochastic model-predictive control approach is assessed on US06 drive cycle. • Reduces temperature excursion instances by ∼ 69% and coolant usage by ∼ 73%. [ABSTRACT FROM AUTHOR]

In this study, a hybrid liquid cold plate design containing Z-type parallel cooling channel and PCM/aluminum foam composite, in conjunction with a novel delayed cooling strategy, is proposed to provide a compact, lightweight, and energy efficient solution for battery thermal management systems (BTMSs). A total of nine different cold plate designs, including one baseline cold plate without PCM composite and eight hybrid cold plates containing PCM composite, are analyzed systematically to demonstrate the superior cooling performance of the proposed cooling design. Specifically, the average temperature of battery surface and total power consumption performance of each design are analyzed and compared at a battery discharging rate of 1C under both continuous and delayed cooling schemes. Subsequently, two selected designs with superior cooling performance as well as the baseline cold plate are further investigated to discuss the effectiveness of hybrid liquid cold plates for cooling batteries at high discharge rates. The results show that the optimum hybrid cold plate design, which only weighs half of the baseline cold plate, can provide more than 50% reduction in the total pumping power while achieving the same cooling performance (i.e., with the average battery temperature controlled within 40 °C) compared with the baseline cold plate at battery discharging rates of 1C, 2C and 3C. These results can potentially provide important guidance to the design of advanced cooling systems for lithium-ion batteries. • A compact and lightweight battery thermal management system is proposed. • A delayed cooling strategy is proposed and analyzed. • Cooling performances were compared between different designs numerically. • Optimum cooling system allows >50% reduction in power consumption and weight. [ABSTRACT FROM AUTHOR]

Thermal management is indispensable to lithium-ion battery pack especially within high power energy storage device and system. To investigate the thermal performance of lithium-ion battery pack, a type of liquid cooling method based on mini-channel cold-plate is used and the three-dimensional numerical model was established in this paper. The effects of number of channels, inlet mass flow rate, flow direction and width of channels on the thermal behaviors of the battery pack were analyzed. The results showed that the mini-channel cold-plate thermal management system provided good cooling efficiency in controlling the battery temperature at 5C discharge. A 5-channel cold-plate was enough and the temperature could be evidently reduced by increasing the inlet mass flow rate. Additionally, for the bad temperature uniformity in the design 1, design 2 was proposed and compared with the design 1. The maximum temperature and temperature difference decreased 13.3% and 43.3%, respectively. Temperature uniformity was significantly improved. [ABSTRACT FROM AUTHOR]

This paper provides a methodology to assess the average surface temperature of battery cells under realistic transient scenarios. Computational fluid dynamics modelling of battery cooling is conducted for the cases exposed to the ramps of internal heat generation inferred from the standard driving cycles. The results are then post-processed to determine the effectiveness of air and water as the coolant fluids. A quantitative measure of the maximum overshoot, dimensionless settling (DST), heating (DHT), and cooling (DCT) time is subsequently presented. It is shown that, compared to water, air produces a considerably delayed response to temporal changes in the internal heat generation and is slower at reaching the new steady state condition. Cooling battery cells by using water almost always ensures remaining within the safe operating range. Nonetheless, regardless of the coolant type, the long period ramps tend to produce smaller values of DST. The primary origin of the delay is the slow heat conduction within the battery cells. In addition, it is shown that water responds to changes in the internal heat generation far quicker during the heating and the cooling phases. The study highlights the importance of transient analyses for characterising the thermal behaviour of battery packs. • A novel measure of battery heat release due to internal heat generation is presented. • Transient cases with sharp gradients cause large delays in system response. • Air cases always produce an overshoot and are far slower at reaching steady state. • Battery cells remain within the safe operating range in almost all water cases. • Water cases react far quicker to changes in the internal heat generation. [ABSTRACT FROM AUTHOR]

An efficient and safe thermal insulation structure design is critical in battery thermal management systems to prevent thermal runaway propagation. In this paper, using a common real-life overcharge as a trigger for battery runaway, we investigate the runaway response of the battery module without thermal insulation and with various thermal insulation materials. The experimental results indicate that the thermal insulation has the effect of stopping the thermal spread of the battery module and reducing the maximum temperature. By comparing the temperature change of the batteries, it is discovered that the fiber-based material has a temperature drop efficiency of 71.83%, while the aerogel materials are at least 13% more efficient in temperature reduction than fibrous materials. Meanwhile, it is demonstrated that by examining the capacity characteristics of the damaged battery and the characteristics of the insulation material, the pre-oxidized silk aerogel has the best thermal spread suppression effect and the TG (thermogravimetric) variation withstood high temperatures of up to 746 °C. SEM (scanning electron microscope) morphology for different insulation materials before and after combustion show that pre-oxidized silk aerogel maintains a strong thermal insulation capacity in the thermal spreading. It is expected to have a guidance for the design of thermal insulation in lithium-ion battery modules. • The greater the overcharge multiplier, the higher the temperature following thermal runaway. • The battery is highly susceptible to TR when the surface temperature exceed 200 °C. • The fiber material have a temperature drop efficiency of 71.83%. • The aerogel materials are at least 13% in temperature reduction than fibrous materials. • The pre-oxidized silk aerogel have the best thermal spread suppression effect. [ABSTRACT FROM AUTHOR]

Lithium-ion (Li-ion) battery cooling using a phase change material (PCM)/compressed expanded natural graphite (CENG) composite is investigated, for a cylindrical battery cell and for a battery module scale. An electrochemistry model (average model) is coupled to the thermal model, with the addition of a one-dimensional model for the solution and solid diffusion using the nodal network method. The analysis of the temperature distribution of the battery module scale has shown that a two-dimensional model is sufficient to describe the transient temperature rise. In consequence, a two-dimensional cell-centred finite volume code for unstructured meshes is developed with additions of the electrochemistry and phase change. This two-dimensional thermal model is used to investigate a new and usual battery module configurations cooled by PCM/CENG at different discharge rates. The comparison of both configurations with a constant source term and heat generation based on the electrochemistry model showed the superiority of the new design. In this study, comparisons between the predictions from different analytical and computational tools as well as open-source packages were carried out, and close agreements have been observed. [ABSTRACT FROM AUTHOR]

Battery thermal management is a very active research focus in recent years because of its great essentiality for electric vehicles. In order to maintain the maximum temperature and local temperature difference in appropriate range, a new kind of cooling method for cylindrical batteries which is based on mini-channel liquid cooled cylinder is proposed in this paper. The effects of channel quantity, mass flow rate, flow direction and entrance size on the heat dissipation performance were investigated numerically. The results showed that the maximum temperature can be controlled under 40 °C for 42,110 cylindrical batteries when the number of mini-channel is no less than four and the inlet mass flow rate is 1 × 10 −3 kg/s. Considering both the maximum temperature and local temperature difference, the cooling style by liquid cooled cylinder can demonstrate advantages compared to natural convection cooling only when the channel number is larger than eight. The capability of reducing the maximum temperature is limited through increasing the mass flow rate. The capacity of heat dissipation is enhanced first and then weakened along with the rising of entrance size, when the inlet mass flow rate is constant. [ABSTRACT FROM AUTHOR]

• A novel design for BTMS is proposed to separate the propagation of thermal runaway. • Th BTMS unites phase change cooling, liquid cooling and thermal insulation material. • The electrochemical-thermal and heat transfer-laminar flow coupling model is built. • The influence of coolant flow rate on the novel BTMS in the extreme case is analyzed. Nowadays, electric vehicles attract much attention due to the advantages of low energy consumption and zero emission. As the power source of electric vehicles, the safe and stable operation of lithium ion battery is very important. However, owing to overcharge, mechanical collision, overheating or other conditions, the battery may occur thermal runaway, which can cause serious accidents such as fire or explosion. To solve this problem, an efficient and energy-saving battery thermal management system becomes a necessary choice. In this paper, a novel integrated battery thermal management system with multi-measure prevention strategy is designed and analyzed, which is mainly composed of the composite phase change material, aerogel and cooling-channel. Firstly, the electrochemical-thermal coupling mathematical model is established, and then the reliabilities of thermal runaway model, phase change cooling model and liquid cooling model are verified, respectively. Next the numerical simulation including the effect of different operating modes, extreme case and coolant flow rate on the battery thermal management system is carried out, and finally the results are discussed in detail. The results show that the battery thermal management system can not only quickly take away the accumulated heat and separate the propagation of thermal runaway, but also maintain the temperature uniformity of battery. [Display omitted] [ABSTRACT FROM AUTHOR]

Lithium-ion batteries (LIBs) are extremely sensitive to their temperature and therefore, require a battery thermal management system (BTMS). BTMS is commonly employed to prevent thermal runaway of the LIB pack by controlling their operating temperature. This review paper provides various cooling strategies, including active and passive approaches, utilized in BTMSs. Air-cooled, liquid-based, and PCM-cooled techniques are first reviewed. This article presents an assessment of the application of nanofluids and nano-phase change materials (nano-PCMs) in BTMSs to improve heat dissipation from the LIB pack. This work emphasizes the utilization of these materials to intensify their thermal conductivity and suggests further investigations on their application in BTMSs. • Lithium-ion batteries are extremely sensitive to their temperature. • BTMS is employed to prevent battery thermal runaway by controlling its temperature. • Providing various cooling strategies for BTMS: active and passive approaches. • Presenting an assessment of the application of nanofluids and nano-PCMs) in BTMSs. [ABSTRACT FROM AUTHOR]

Mini channeled cold plates (MCCP) are an impressive choice for electric vehicles with a liquid-based thermal management system to keep the battery temperature within the desired range and to achieve a homogeneous temperature distribution. This paper came up with an optimum solution for maximum battery temperature (MBT), maximum temperature difference on the battery surface (MTD) and pressure drops in the channels (ΔP), which are vital parameters. Multi-objective optimization of geometric parameters and coolant flow rate of a designed MCCP which is experimentally investigated is carried out using the Desirability Function Approach. Firstly, the design of experiments (DoE) is generated using response surface method after determining the input variables and their levels. Then, each sample of DoE are modeled and analyzed numerically. Furthermore, the regression equations of the objective functions (MBT, MTD and ΔP) depending on the design parameters are developed and their variance analyzes are performed. Prediction accuracies of model equations developed for MBT, MTD and ΔP are 97.75%, 95.49% and 97.15%, respectively. As a result, optimum values of design variables, namely channel width (mm), distance between branches (mm), channel depth (mm), number of crossovers in branches and coolant flow rate (l/min) are 5, 5, 10, 13 and 0.7061, respectively. • Multi-objective optimization of a mini channeled cold plate. • Simulation of temperature distribution on the battery surface for different cases. • Deriving regression equations for the optimization output variables. • Achieving a minimum prediction accuracy rate of 95.49% for the response parameters. [ABSTRACT FROM AUTHOR]

The thermal management of a cylindrical battery cell by a phase change material (PCM)/compressed expanded natural graphite (CENG) is investigated in this study. The transient thermal behaviour of both the battery and the PCM/CENG is described with a simplified one-dimensional model taking into account the physical and phase change properties of the PCM/CENG composite. The 1D analytical/computational model yielded nearly identical results to the three-dimensional simulation results for various cooling strategies. Therefore, the 1D model is sufficient to describe the transient behaviour of the battery cooled by a PCM/CENG composite. Moreover, the maximum temperature reached by the PCM/CENG cooling strategy is much lower than that by the forced convection in the same configuration. In the test case studied, the PCM showed superior transient characteristics to forced convection cooling. The PCM cooling is able to maintain a lower maximum temperature during the melting process and to extend the transient time for temperature rise. Furthermore, the graphite-matrix bulk density is identified as an important parameter for optimising the PCM/CENG cooling strategy. [ABSTRACT FROM AUTHOR]

In order to guarantee the safety and extend the cycle life of Li-ion power batteries within electric vehicles, a mini-channel cold plate-based battery thermal management system is designed to cool a rectangular Li-ion battery. A three-dimensional thermal model of the cooling system was established and the effects of number of channels, flow direction, inlet mass flow rate and ambient temperature on temperature rise and distribution of the battery during the discharge process were investigated. The results suggest that the maximum temperature of the battery decreases with increases in the number of channels and inlet mass flow rate. The effect of flow direction on cooling performance was smaller after mass flow rate increased. The cooling performance improved with the increase of inlet mass flow rate but the increasing trend became smaller, and the mass flow rate as 5 × 10 −4 kg s −1 was optimal. The simulation results will be useful for the design of mini-channel cold plate-based battery thermal management system. [ABSTRACT FROM AUTHOR]

Thermal management needs to be carefully considered in the lithium-ion battery module design to guarantee the temperature of batteries in operation within a narrow optimal range. This article firstly explores the thermal performance of battery module under different cell arrangement structures, which includes: 1 × 24, 3 × 8 and 5 × 5 arrays rectangular arrangement, 19 cells hexagonal arrangement and 28 cells circular arrangement. In addition, air-cooling strategies are also investigated by installing the fans in the different locations of the battery module to improve the temperature uniformity. Factors that influence the cooling capability of forced air cooling are discussed based on the simulations. The three-dimensional computational fluid dynamics (CFD) method and lumped model of single cell have been applied in the simulation. The temperature distributions of batteries are quantitatively described based on different module patterns, fan locations as well as inter-cell distance, and the conclusions are arrived as follows: when the fan locates on top of the module, the best cooling performance is achieved; the most desired structure with forced air cooling is cubic arrangement concerning the cooling effect and cost, while hexagonal structure is optimal when focus on the space utilization of battery module. Besides, the optimized inter-cell distance in battery module structure has been recommended. [ABSTRACT FROM AUTHOR]

The present study introduces a novel fin–Phase Change Material (PCM)–Expanded Graphite (EG) composite for better thermal management of a Panasonic NCR18650BD battery at discharge rates higher than its maximum discharge limit 2C. Fins and EG are augmented with PCM to enhance its effective thermal conductivity. Initially, the electrical and thermal behaviors of the battery are simulated for 0.5, 1, and 2C discharge rates using the Newman P2D model, and these are validated against in-house experiments. Following this, the heat generation profiles are estimated from the numerical model to mimic the battery with a heater in the experiments conducted to propose an effective thermal management system for 2, 3, and 4C discharge rates. Three heat sinks, one sans fins, and the other two with 130 and 260 fins, respectively, are considered to perform experiments. Phase Change Material (PCM) named Eicosane (Ei) with an addition of 0, 10, 20, 25, and 30% weight fractions of EG is filled in the heat sinks to study the effect of composite PCM on the thermal regulation of the battery. The heat sink having 260 fins filled with 70% Ei - 30% EG composite outperforms the other heat sinks considered in this study by recording lower temperatures to the extent of 17.5, 20.5, and 22.7 °C than a plain heat sink filled with 100% Eicosane for discharge rates 2, 3, and 4C, respectively. Furthermore, with the addition of 30% EG by volume, the maximum thermal performance of heat sink having 130 fins surpasses the heat sink having 260 fins filled with pure Eicosane by recording 1.3, 0.5, and 1.5 °C lower temperatures for discharge rates 2, 3, and 4C, respectively. In view of this, a possible engineering solution is to employ a simple heat sink, having fewer fins filled with PCM–EG composite instead of intricate heat sinks, having more fins filled only with the baseline PCM, to overcome the design difficulties and manufacturing costs. • Introduced fin–PCM–EG composite heat sink for thermal management of Li-ion batteries. • Newman P2D model is used to calculate the heat generation for 2, 3, and 4C rates. • Compared performance of different heat sinks for 2, 3, and 4C rates experimentally. • Heat sink with 260 fins and 70% Ei - 30% EG outperforms all other combinations. • Addition of EG helps to propose a less intricate and more efficient heat sink. [ABSTRACT FROM AUTHOR]

• A numerical analysis is performed for direct liquid cooling of lithium-ion batteries using different dielectric fluids. • Study and compared the thermal performance of three different dielectric fluids including mineral oil, deionised water, and one engineered fluid. • The temperature rise is limited to below 3 °C for 1c- discharge by using deionised water at all mass flow rates, where oil-based fluids are delivering better performance only at higher mass flow rates of 0.05 kg/s. • The mineral oil and engineered fluids deliver almost an equal thermal performance, however, the latter consumed 76.43% less power at a mass flow rate of 0.05 kg/s. Lithium-ion battery (LIB) cells are responsible for powering most electric vehicles. LIB is still a superior battery available in the market because of its high energy density, specific power, and long cycle life. However, LIB comes with the challenges like thermal management as it is highly sensitive to temperature. Amongst different cooling methods, direct liquid cooling, also known as immersion cooling, can deliver a high cooling rate mainly because of its complete contact with the heat source. The single-phase liquid immersion with dielectric fluids (DELC) offers safety and cooling performance with lower parasitic power consumption and space requirements. This research involves studying and comparing different DELC's for the direct cooling of lithium-ion batteries. A numerical analysis of the 4S1P arrangement of LIB cells with direct cooling is conducted with three different DELC's including deionised water, mineral oil, and an engineered fluid. The transient behaviour of the battery module for various mass flow rates of DELC and at 1C,2C,3C-discharge rates are examined. All DELC maintains an excellent temperature homogeneity within the individual cells and LIB cells. The DELC with higher specific heat and thermal conductivity is suitable for cooling the LIB cells during high discharge conditions. However, all the dielectric fluids studied here effectively limit the temperature rise below 5 °C at 2-C discharging operation when the mass flow rate is increased to 0.05 kg/s. This improvement in thermal performance comes at the expense of extra power consumption. Even though both DELC-2 and DELC -3 delivered almost similar temperature rise values of 6.1, 5.2 °C, respectively during 2C discharging operation, the latter consumed 76.43% less power at a mass flow rate of 0.05 kg/s. For this reason, engineered fluids with lower viscosity values can be preferred over mineral oils. The deionised water is more effective for limiting the temperature rise below 2.2 °C for 3C discharging with the least parasitic power consumption of 0.52 mW at a mass flow rate of 0.05 kg/s. A variable cyclic load matching HWFET-driving cycle has been applied to the battery pack with all three DELCs, and all three fluids limited temperature rise below 1 °C. [ABSTRACT FROM AUTHOR]

A simplified one-dimensional transient computational model of a prismatic lithium-ion battery cell is developed using thermal circuit approach in conjunction with the thermal model of the heat pipe. The proposed model is compared to an analytical solution based on variable separation as well as three-dimensional (3D) computational fluid dynamics (CFD) simulations. The three approaches, i.e. the 1D computational model, analytical solution, and 3D CFD simulations, yielded nearly identical results for the thermal behaviours. Therefore the 1D model is considered to be sufficient to predict the temperature distribution of lithium-ion battery thermal management using heat pipes. Moreover, a maximum temperature of 27.6 °C was predicted for the design of the heat pipe setup in a distributed configuration, while a maximum temperature of 51.5 °C was predicted when forced convection was applied to the same configuration. The higher surface contact of the heat pipes allows a better cooling management compared to forced convection cooling. Accordingly, heat pipes can be used to achieve effective thermal management of a battery pack with confined surface areas. [ABSTRACT FROM AUTHOR]

Abstract: Many portable devices such as soldier carrying devices are powered by low-weight but high-capacity lithium ion (Li-ion) batteries. An effective battery thermal management (BTM) system is required to keep the batteries operating within a desirable temperature range with minimal variations, and thus to guarantee their high efficiency, long lifetime and great safety. However, the rigorous constraints imposed by the budgets in weight and volume for this specific application eliminate the possible consideration of many existing classical cooling approaches and make the development of BTM system very challenging in this field. In this paper, a flexible hydrogel-based BTM system is developed to address this challenge. The proposed BTM system is based on cost-effective sodium polyacrylate and can be arbitrarily shaped and conveniently packed to accommodate any Li-ion stacks. This BTM system is tested through a series of high-intensity discharge and abnormal heat release processes, and its performance is compared with three classical BTM systems. The test results demonstrate that the proposed low-cost, space-saving, and contour-adaptable BTM system is a very economic and efficient approach in handling the thermal surge of Li-ion batteries. [Copyright &y& Elsevier]

• Lithium-ion battery module and thermal management interactions were simulated. • The system was thermally managed using fuel. • A comparative analysis was performed for verification and assessment. • N-heptane fuel was found as a feasible coolant in hybrid electric vehicle batteries. Battery thermal management system (BTMS) design is crucial for its performance, which can be associated with extra costs and system complexity. Most of the current studies are focused on the BTMS design but with a little focus on the improvement of coolants. In this work, the feasibility of using combustion engine fuel for the LIB thermal management of hybrid electric vehicles is investigated. N-heptane is used as a dielectric hydrocarbon coolant in the introduced system. The thermal performance of the proposed system is investigated numerically using the CFD software ANSYS-Fluent. To benchmark and validate the system performance, a comparative study is made among other common approaches, including the use of air and 3M-Novec 7200. A variety of input parameters are accounted for, including inlet velocities and discharge rates. The results show that air cooling is the least effective method to control the battery module temperature uniformity and the Li-ion battery safety limit. At the same time, n-heptane and 3M-Novec 7200 have shown good control of the module temperature range (20 °C–40 °C) at various discharge rates and different inlet velocities. However, using n-heptane is a considerable improvement to the cost of the system and reduction in its weight and maximum temperature, compared to that using 3M-Novec 7200 coolant. For instance, at 0.1 m · s - 1 , n-heptane has reduced the Li-ion battery maximum temperature at 1 C and 2 C discharge rates by more than 7.9 °C (2.6%) and 17.9 °C (5.65%), respectively, compared to those predicted using the same battery module without cooling. [ABSTRACT FROM AUTHOR]

• The cold plates of battery liquid cooling system are designed by topology optimization. • Consider the two cold plate models the inlet and outlet on the centerline or the diagonal. • Compare the numerical results of design cold plates with rectangular-channel and serpentine-channel cold plates. • Topology optimization cold plates have better cooling performance and lower flow resistance at the same inlet pressure. • The change of inlet pressure has an impact on the cooling effect of the cold plates. In this paper, the cold plates are designed to cool the rectangular lithium-ion battery packs by the topology optimization method. The topology optimization method obtains the channel structure in the two-dimensional model, and three-dimensional cold plate models are then established according to their two-dimensional structure. In a simple model for a battery pack, numerical analyses of topology optimization cold plate (TCP) are implemented using COMSOL software. Numerical results were compared with conventional rectangular-channel cold plate (RCP) and serpentine-channel cold plate (SCP) to investigate the cooling performance and flow characteristics of the cold plate. The results demonstrate that the flow channel structure of the cold plate has a significant influence on the temperature distribution of the battery. At 150 Pa inlet pressure, the maximum temperature of batteries with TCPs is reduced by 0.27% and 1.08% compared to that with RCP or SCP, and the temperature difference is lowered by 19.50% and 41.88%. Appropriately increasing the inlet pressure of the cold plate can also reduce the maximum temperature and temperature difference of batteries. Due to low flow resistance and high heat transfer coefficient, topology optimization will be widely used to design battery cold plates. [ABSTRACT FROM AUTHOR]

Serious performance loss of lithium-ion batteries at subzero temperatures is the major obstacle to promoting battery system in cold regions. This paper proposes a novel heating strategy to heat battery from extremely cold temperatures based on a battery-powered external heating structure. The strategy contains two stages: preheating process for battery cold-start, and temperature holding process for battery temperature control after preheating. The strategy switches from the preheating to the temperature holding according to the power capability of battery pack. Both the electrical and thermal behaviors of battery pack are described based on equivalent circuit models, and the state-of-charge and state-of-power of battery pack are co-estimated online to support the implementation of the strategy. Systematic battery-in-the-loop tests are conducted for a series-connected battery pack to verify the effectiveness of the strategy at – 40 °C. Experimental results show that the battery pack can not only be heated from −41.4 °C to −14.0 °C in 371 s by consuming 6.1% of nominal capacity without being over-discharged, but also output 64.81% and 66.59% of nominal energy for loading the modified dynamic stress test cycles and the modified federal urban driving schedule cycles respectively after preheating. [ABSTRACT FROM AUTHOR]

• Design of a liquid cooling system for EV batteries based on the constructal law • Canopy-to-canopy architectures prove to have high thermal efficiency • They allow to maintain the battery cell below the critical temperature level With the growing interest on electric vehicles comes the question of the thermal management of their battery pack. In this work, we propose a thermally efficient solution consisting in inserting between the cells a liquid cooling system based on constructal canopy-to-canopy architectures. In such systems, the cooling fluid is driven from a trunk channel to perpendicular branches that make the tree canopy. An opposite tree collects the liquid in such a way that the two trees match canopy-to-canopy. The configuration of the cooling solution is predicted following the constructal methodology, leading to the choice of the hydraulic diameter ratios. We show that such configurations allow extracting most of the non-uniformly generated heat by the battery cell during the discharging phase, while using a small mass flow rate. [ABSTRACT FROM AUTHOR]

Abstract: This work studied the thermal management of lithium ion batteries both numerically and experimentally. Numerically, a two dimensional CFD (computational fluid dynamics) model has been developed to perform detailed simulations of the thermal management issues within a battery pack cooled by air. Experimentally, systematic tests were performed to provide datasets to validate the CFD model. The main components in the experimental facility included a multi-cell battery pack and a wind tunnel. The wind tunnel facility generated well-controlled cooling air flow with velocity up to 30 m s−1 (∼67 miles per hour). So that the study can be performed under flow conditions directly relevant to practice. The major contributions from this combined numerical-experimental study are threefold. First, the CFD model has been shown to capture the dynamics of the cooling of battery modules consisting of multiple battery cells, including temperature non-uniformity among cells. Second, the CFD simulations have been compared directly against experimental data to quantify the accuracy and validity of the CFD models. Third, based on the validated CFD models, a reduced-order model is developed to predict the maximum cell temperature in the battery module. The accuracy and simplicity of the reduced-order model makes it promising for in situ monitoring and control purposes. [Copyright &y& Elsevier]

Abstract: The time-efficient yet accurate thermal modeling of the battery cells for electric and hybrid electric vehicles is essential improving the performance, safety, and lifetime of the battery system. This paper presents a spatial-resolution, lumped-capacitance (LC) thermal model for cylindrical battery cells under high Biot number (Bi⩾1) conditions where the classical LC thermal model is generally inapplicable because of a significant temperature variation in the cell volume. The spatial-resolution LC model was formulated using zero- and first-order Hermite integral approximations. For model validation, a one-dimensional, transient analytical (exact) solution using Green functions was obtained for a cylindrical Li-ion battery cell with uniform volumetric battery heat generation of Joule and entropic heating under convective cooling boundary conditions. It was found from the comparison of the results that the spatial-resolution LC thermal model can accurately and quickly predicts the cell temperatures (core, skin and area-averaged) under various dynamic battery duty cycles even for high Biot numbers due to highly convective conditions such as liquid cooling. [Copyright &y& Elsevier]

Abstract: Time-dependent, thermal behaviour of a lithium-ion (Li-ion) polymer cell has been modelled for electric vehicle (EV) drive cycles with a view to developing an effective battery thermal management system. The fully coupled, three-dimensional transient electro-thermal model has been implemented based on a finite volume method. To support the numerical study, a high energy density Li-ion polymer pouch cell was tested in a climatic chamber for electric load cycles consisting of various charge and discharge rates, and a good agreement was found between the model predictions and the experimental data. The cell-level thermal behaviour under stressful conditions such as high power draw and high ambient temperature was predicted with the model. A significant temperature increase was observed in the stressful condition, corresponding to a repeated acceleration and deceleration, indicating that an effective battery thermal management system would be required to maintain the optimal cell performance and also to achieve a full battery lifesapn. [Copyright &y& Elsevier]

The optimal performance of a Li-ion battery is directly impacted by temperature. In order to control the temperature rise and provide even temperature distributions in the battery pack, a thermal management scheme comprises thin heat sinks with multiple phase change materials (PCMs) and air channels is investigated in this paper. The cooling performance and temperature homogenization of the battery thermal management (BTM) system are carefully studied under various configurations of PCMs. The results show that increasing the air inlet velocity has less effect in suppressing the temperature rise at early discharge stage, but ameliorates as the discharge prolonged to 3600 s. The standard deviation of the temperature (STDV) and maximum temperature of the batteries can be decreased by arranging PCMs with a lower melting temperature at the midsection and a higher melting temperature at the air outlet region of the heat sinks. In addition, for volume fraction of PCMs, Case IV, having a PCM with a higher melting point adjacent to the air outlet region and occupying one-half the height of the heat sink, illustrates a lower temperature rise and decreases the maximum temperature in the battery module by 1.024 K, 2.186 K, and 2.553 K, compared to Case I, II, and III, respectively. • Multiple PCMs incorporated thin heat sinks for battery thermal management is proposed. • The thermal performance of the battery based on maximum temperature upsurge is investigated. • The distributions of PCMs based on melting point and latent heat were carefully explored. • The optimal design for the distribution of PCMs is obtained for the proposed battery. [ABSTRACT FROM AUTHOR]

l The critical thermal issues of lithium-ion batteries are introduced. l The design principles for batteries thermal management are presented. l The latest advances on battery thermal management systems are summarized. l Emerging technologies for next-generation power batteries are discussed. Replacing conventional gasoline-powered cars with electric vehicles (EVs) can reduce not only pollution emissions but also the dependence on fossil fuels. As the most widely used power source to propel EVs, lithium-ion batteries are highly sensitive to the operating temperatures, rendering battery thermal management indispensable to ensure their high performance, long cycle life and safe operation. In this review, we summarize the recent advances in thermal management for lithium-ion batteries. The critical thermal issues caused by high temperature, low temperature and temperature non-uniformity are firstly discussed. The design principles and the existing thermal management systems are then presented and elaborated extensively. Emerging technologies such as thermoelectric devices and internal heating methods for future battery thermal management are analyzed. We highlight that the combination of passive and active cooling/heating methods is promising to meet the stringent thermal requirements, particularly under dynamic conditions with drastic power fluctuations. Finally, the remaining challenges and perspectives of thermal management systems with high efficiency and durability are provided. This review offers comprehensive guidance on the design of advanced thermal management system for next-generation power batteries. [ABSTRACT FROM AUTHOR]

It is important for the safety and good performance of a Li-ion battery module/pack to have an efficient thermal management system. In this paper, a battery thermal management system with a two-phase refrigerant circulated by a pump was developed. A battery module consisting of 240 18650-type Li-ion batteries was fabricated based on a finned-tube heat-exchanger structure. This structural design offers the potential to reduce the weight of the battery thermal management system. The cooling performance of the battery module was experimentally studied under different charge/discharge C-rates and with different refrigerant circulation pump operation frequencies. The results demonstrated the effectiveness of the cooling system. It was found that the refrigerant-based battery thermal management system could maintain the battery module maximum temperature under 38 °C and the temperature non-uniformity within 2.5 °C for the various operation conditions considered. The experimental results with 0.5 C charging and a US06 drive cycle showed that the thermal management system could reduce the maximum temperature difference in the battery module from an initial value of 4.5 °C to 2.6 °C, and from the initial 1.3 °C to 1.1 °C, respectively. In addition, the variable pump frequency mode was found to be effective at controlling the battery module, functioning at a desirable constant temperature and at the same time minimizing the pump work consumption. [ABSTRACT FROM AUTHOR]

The battery thermal management system (BTMS) is important to ensure the lithium-ion battery life, performance, and safety. A novel inclined U-shaped flat microheat pipe array (FMHPA) is used for BTMS to achieve high efficiency and space-saving in this study. The thermal control performance is experimentally studied and compared with the module without FMHPAs. Results show that the equivalent thermal conductivity of the inclined U-shaped FMHPA is approximately 4350 W m−1 K−1, and plays the role of core heat transfer element. The maximum temperature and temperature difference of the module with FMHPAs are reduced by 16% and 60%, respectively, compared with those of the module without FMHPAs; FMHPAs keep the module in a suitable temperature range for most of the time in the ambient temperature of 25 °C during the 1C charge–2C discharge cycle. Moreover, the temperature difference at cell and module level are maintained within 5 °C in ambient temperature of 25 °C and 40 °C. The heating rate of the module with FMHPAs reaches 0.61 °C/min under the temperature difference of less than 5 °C; variable power heating (from large to small) will increase the temperature rise rate of the battery by 0.19 °C/min. • Inclined U-shaped flat microheat pipe array is used in battery module. • The module with inclined U-shaped FMHPAs is compact in structure and saves space. • The separation of the coolant and batteries improves safety. • Module is kept in suitable temperature in 1C charge–2 C discharge cycle. • Temperature difference at cell and module level are maintained within 5 °C. [ABSTRACT FROM AUTHOR]

• Liquid cooling of pouch type li-ion batteries with multi-stage Tesla valve proposed • Channel geometry, coolant properties optimized numerically from COMSOL simulation • Forward and reverse flow configuration across the multi-stage Tesla valve explored • An enhanced heat transfer in the reverse flow observed at the cost of pressure drop • Maximum cold plate temperature noted within 40°C for Re varying from 2500 to 4750 The operating temperature can significantly influence the performance, cycle life, and safety of Li-ion batteries used in electric vehicles. One of the critical factors is to assess the temperature distribution within the battery pack when operated under extreme conditions and choosing an appropriate cooling method. Concerning this, a liquid cooling plate comprising Tesla valve configuration with high recognition in microfluidic applications is proposed to provide a safer temperature range for pouch type Li-ion batteries. A multi-stage Tesla valve with forward and reverse flow configuration is designed and analysed to improve a conventional rectangular channel's intrinsic temperature gradient issues for turbulent flow conditions. Moreover, the influence of various parameters such as channel number, the distance between two consecutive valves, coolant temperature, and heat flux applied on the cold plate's top and bottom surfaces are numerically investigated for varying Reynold's number using COMSOL Multiphysics software. An enhancement in heat transfer with the reverse flow in multi-stage Tesla valve is seen, mainly caused by flow bifurcation and mixing mechanisms, at the cost of pressure drop. A cold plate with 4 channels and valve to valve distance of 8.82 mm exhibits the most effective cooling performance. [ABSTRACT FROM AUTHOR]