A Review of Advanced Cooling Strategies for Battery Thermal Management Systems in Electric Vehicles
Abstract
:1. Introduction
2. Thermal Characteristics of Li-Ion Battery
2.1. Heat Generation in Li-Ion Battery
2.2. Thermal Issues in Li-Ion Battery
3. Battery Thermal Management with Conventional Cooling Strategies
3.1. Air Cooling
3.2. Indirect Liquid Cooling
4. Battery Thermal Management System with Advanced Cooling Strategies
4.1. Phase Change Material Cooling
4.2. Direct Liquid Cooling
5. Summary and Recommendations
- (a)
- In the early stages, air cooling with the advantages of simple structure, low cost, easy installation and maintenance, and no leakage issue was widely used for battery thermal management. However, the low thermal conductivity of the air makes it suitable only for battery thermal management with low heat dissipation requirements.
- (b)
- Compared to air, liquids have a better thermal conductivity and higher specific heat capacity. Therefore, indirect liquid cooling demonstrated superior ability to control the maximum temperature and temperature distribution of the battery compared to air cooling. For large-scale battery thermal management, indirect liquid cooling is a more effective cooling strategy than air cooling. However, some concerns in particular for indirect liquid cooling such as complex structure, larger energy consumption, heavier overall weight, liquid leakage, and an increased thermal resistance between the battery cell and the coolant are obstacles to consider for future higher-capacity electric vehicle applications.
- (c)
- From the extensive research conducted on air cooling and indirect liquid cooling for battery thermal management in EVs, it is observed that these commercial cooling techniques could not promise improved thermal management for future, high-capacity battery systems despite several modifications in design/structure and coolant type. There is a need to propose a suitable cooling strategy considering the target energy density of the EV battery which is expected to be attained in the future. Therefore, phase change material cooling and direct liquid cooling were recently investigated as an alternative to conventional, commercial cooling strategies with a vision to employ them in future generations of battery cooling systems.
- (d)
- The heat dissipation efficiency of phase change material cooling is excellent as it uses a larger latent heat when the phase change occurs. The phase change material cooling provides an enhanced temperature uniformity for the battery when the battery’s temperature approaches the melting point temperature of the phase change material. The addition of carbon materials or metal foam can greatly improve the thermal conductivity of phase change materials, which has a positive effect on the temperature uniformity of the battery pack. However, it is necessary to consider the balance between latent heat and conduction heat, filling density, pore size, and mass fraction to avoid affecting the natural convection of liquid phase change material.
- (e)
- The performance of phase change material cooling decreases when the temperature of the battery is higher than its melting point temperature. The thermal conductivity of phase change material is low, which forces additives to improve heat dissipation performance. The control of temperature rise and temperature difference of the battery could be excellent for phase change material cooling when it is combined with a heat pipe, cold plate, microchannel cooling plate, fin structure, and liquid cooling. This hybrid battery thermal management system is bulky and impractical for long-term commercial applications.
- (f)
- Direct liquid cooling eliminates the thermal resistance between the battery and the coolant and thus significantly enhances the heat dissipation efficiency. Furthermore, direct liquid cooling when employed with low boiling temperature coolant enables the benefit of two-phase cooling which has a superior heat transfer coefficient compared to single-phase direct liquid cooling and indirect liquid cooling. Therefore, irect liquid cooling can maintain the battery’s maximum temperature and temperature uniformity under a permissible operating range under fast and high charging/discharging conditions and even in extreme conditions, it could prevent thermal runaway propagation effectively.
- (g)
- There are several factors such as coolant type, coolant flow direction, flow rate, coolant immersion height, ambient temperature, and packing compartment pressure which have a strong impact on battery thermal characteristics with direct liquid cooling. The recommended coolants for immersion cooling are dielectric fluid, hydrofluoroethers, hydrocarbons, esters, mineral oils, silicone oils, and water-glycol mixtures, based on relevant properties such as viscosity, density, thermal conductivity, electrical conductivity, specific heat, boiling point/flash point and GWP.
- (h)
- Based on this review of recent research studies and the points discussed above, it is expected that direct liquid cooling has the potential to be considered as an advanced cooling strategy for battery thermal management in next-generation EVs. However, to commercialize direct liquid cooling at a larger scale, some key issues such as complexity in evaporation and condensation modes of coolant, coolant flow distribution, higher pump loss with high viscosity coolants, high cost of coolants, increased fluid weight, and material compatibility need to be addressed. Therefore, comprehensive research is still needed to propose optimal solutions for Li-ion batteries with direct liquid cooling systems in future EVs.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
Nomenclature & Abbreviation
I | operating current (A) |
Qirreversible | reversible heat generation (W) |
Qreversible | reversible heat generation (W) |
Qtotal | total heat generation (W) |
T | battery temperature (°C) |
U | open circuit voltage (V) |
V | operating voltage (V) |
CO2 | carbon dioxide |
C-rate | charging/discharging rate |
EV | electric vehicle |
HP | heat pipe |
IC | internal combustion |
Li-ion | lithium-ion |
SOH | state of health |
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Review | Focus of Review | Highlights |
---|---|---|
Deng et al. (2018) [20] | Battery thermal management based on liquid cooling | Summary of types of liquid cooling structures, the performance of various coolants, and battery pack design |
Chen et al. (2019) [21] | Battery thermal management based on phase change material cooling | Summary of battery cooling research works on pure, composite, and hybrid phase change materials |
Wu et al. (2019) [22] | Battery thermal management based on liquid and heat pipe cooling | Summary of research works on direct liquid cooling, indirect liquid cooling, and heat pipe cooling |
Akinlabi and Solyali (2020) [23] | Battery thermal management based on air cooling | Summary of research works on active and passive air cooling of the battery |
Karthik et al. (2020) [24] | Battery thermal management based on air cooling, liquid cooling, and phase change material cooling | Summary of articles on various cooling strategies to mitigate the thermal runaway propagation in battery |
Thakur et al. (2020) [25] | Battery thermal management based on air, liquid, and heat pipe cooling | Summary of research works on natural and forced air cooling, direct and indirect liquid cooling, and heat pipe cooling for battery |
Tete et al. (2021) [26] | Battery thermal management based on air, liquid, heat pipe, phase change material, and refrigeration cooling | Summary of experimental and numerical research works on battery thermal management systems for hybrid EVs and full EVs |
Murali et al. (2021) [27] | Battery thermal management based on passive phase change material cooling | Summary of research on various battery cooling strategies combined with phase change material. In addition, the research on composite phase material cooling for the battery is also summarized |
Jiang et al. (2022) [28] | Battery thermal management based on air, liquid, heat pipe, phase change material, and combined cooling | Summary of research on battery thermal management with various cooling strategies under normal and abusive conditions |
Hamed et al. (2022) [29] | Battery thermal management based on air, liquid, and phase change material cooling | Summary of research studies on external cooling strategies for the battery |
Roe et al. (2022) [30] | Battery thermal management system based on immersion cooling | Summary of various dielectric fluids for immersion cooling of battery and related research works |
Zhao et al. (2023) [31] | Battery thermal management based on liquid cooling | Research studies focus on optimization and design improvement of liquid cooling systems for batteries are summarized |
Reference | Design Improvements | Key Findings |
---|---|---|
Shahid et al. (2018) [51] | Wedge-shaped inlet plenum with an optimized separating plate for air cooling system | Maximum temperature was reduced by 18.3% and the temperature uniformity was maintained at less than 5 °C |
Na et al. (2018) [52] | Unidirectional airflow and reverse layered airflow configurations for a cylindrical battery module. | Reverse layered airflow configuration significantly reduces the maximum temperature and increases the temperature uniformity of the battery pack compared to unidirectional airflow configuration |
Fan et al. (2019) [53] | Air-cooling of the battery pack with cells arranged in aligned, cross, and staggered arrangements | Battery pack with aligned cells provides the best temperature uniformity and the lowest energy consumption compared to other arrangements |
Yuanzhi Liu et al. (2019) [54] | Air cooling system with J-type, U-type, and Z-type structures | Air cooling system with a J-type structure shows the best thermal management performance compared to the other two structures, with a temperature rise of the battery reduced to 31.18% |
Kai et al. (2020) [55] | A symmetrical air-cooling system with asymmetrical distribution of cell spacing | The maximum cell temperature difference was reduced by 43% and the energy consumption was reduced by 33% compared with the asymmetrical air-cooling system |
Hou et al. (2022) [56] | Optimize the parallel channel width distribution and plenum angle for the air-cooled battery thermal management system | The temperature difference of the battery pack reduces by 49% after optimizing the parallel channel width and 56% after optimizing the plenum angle |
Zhang et al. (2021) [57] | Forced-air cooling system with multiple vents, different position and size of vents and various cell spacings | The maximum temperature and temperature difference of battery were reduced by 16.4% and 48.7%, respectively, for optimized model compared to original model |
Saechan et al. (2022) [58] | Optimize the cell arrangement structure for air cooling | Superior cooling performance for an optimal arrangement distance between cells as 1.5 mm |
Reference | System Specifications | Key Findings |
---|---|---|
Du et al. (2018) [60] | Water cooling tubes for cylindrical battery | Achieves maximum temperature of 31.8 °C and temperature uniformity of 4.2 °C under 1C discharge rate |
Lv et al. (2019) [61] | Water cooling tubes for cylindrical battery | Maximum temperature and temperature uniformity of battery as 42 °C and 4–5 °C, respectively at 3C discharge rate |
Zhou et al. (2019) [62] | Water cooling with a half helical duct for cylindrical battery | Proposed cooling shows battery maximum temperature and temperature uniformity as 30.9 °C and 4.3 °C, respectively under a 5C discharge rate |
Shang et al. (2019) [63] | Water and glycol mixture-based cooling plate for prismatic battery | Cooling configuration attends the maximum temperature and temperature uniformity of battery as 38.89 °C and 5.31 °C, respectively at a 1.2C discharge rate |
Deng et al. (2019) [64] | Cold plate cooling with water for rectangular battery | Maintains the maximum temperature and temperature difference at 31.18 °C and 1.15 °C under 5C discharge rate |
Xu et al. (2019) [65] | Water jacket cooling for prismatic battery | The achievable maximum temperature and temperature uniformity are 32.5 °C and 1.5 °C under a 1C discharge rate |
Li et al. (2019) [66] | Cold plate cooling using water for prismatic battery | The battery maximum temperature and temperature uniformity are maintained within 41.92 °C and 1.78 °C for a 5C discharge rate |
Chen et al. (2019) [67] | Mini channels-based jacket cooling using water for soft-pack battery | The proposed cooling restricts the maximum temperature and temperature uniformity of the battery within 32.8 °C and 2 °C under 1C discharge rate |
Wiriyasart et al. (2020) [68] | Nanofluid flow in corrugated mini channels for battery module cooling | The proposed cooling module shows a maximum temperature lower by 28.65% compared to the conventional cooling module |
Du et al. (2020) [69] | Water cooling plate for pouch battery | Under 2C discharge rate, maintains maximum temperature and temperature difference at 32 °C and 6.2 °C |
Patil et al. (2020) [70] | U-shaped mini channels cooling for pouch cell battery | The maximum temperature and temperature uniformity is maintained below 40 °C and 4 °C for a 50 V battery pack |
Liu et al. (2020) [71] | Water and liquid metal-based cooling tubes for pouch cell battery | Proposed cooling achieves maximum temperature and temperature difference of battery below 40 °C and 5 °C, respectively at a 5C discharge rate |
Monika et al. (2021) [72] | Rectangular mini-channel cold plate sandwiched between the battery cells and providing a constant flow of coolant in the mini-channels across the cold plate. | A cold plate consisting of 4 mm width, parallel flow design with water inlet near the charging port, and coolant flow rate and temperature of 0.003 kg·s −1 and 25 °C, respectively show superior battery cooling performance |
Yates et al. (2021) [73] | Water cooling channels for cylindrical battery | Maximum temperature and temperature difference of battery are restricted within 39.85 °C and 3.15 °C, respectively under a 5C discharge rate |
Huang et al. (2022) [74] | Optimize the cooling plate structure | The optimized structure improves the cooling efficiency by 10.82% compared with the original design |
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Garud, K.S.; Tai, L.D.; Hwang, S.-G.; Nguyen, N.-H.; Lee, M.-Y. A Review of Advanced Cooling Strategies for Battery Thermal Management Systems in Electric Vehicles. Symmetry 2023, 15, 1322. https://doi.org/10.3390/sym15071322
Garud KS, Tai LD, Hwang S-G, Nguyen N-H, Lee M-Y. A Review of Advanced Cooling Strategies for Battery Thermal Management Systems in Electric Vehicles. Symmetry. 2023; 15(7):1322. https://doi.org/10.3390/sym15071322
Chicago/Turabian StyleGarud, Kunal Sandip, Le Duc Tai, Seong-Guk Hwang, Nghia-Huu Nguyen, and Moo-Yeon Lee. 2023. "A Review of Advanced Cooling Strategies for Battery Thermal Management Systems in Electric Vehicles" Symmetry 15, no. 7: 1322. https://doi.org/10.3390/sym15071322