Search Results (25)

Silicone oil is a promising dielectric coolant for battery immersion cooling, yet the ability of commercially available conductivity sensors to detect battery-related contamination remains poorly quantified. In this study, simulated carbonaceous particles, electrolyte, and mixed solid–liquid contaminants were introduced into silicone oil under controlled conditions using a closed-loop circulation platform, and conductivity was monitored in real time. Pristine silicone oil exhibited a baseline conductivity near the instrumental detection limit (approximately 1.26 μS·cm⁻¹). No measurable conductivity increase was observed for particle concentrations up to 10 g·L⁻¹ or electrolyte additions up to 3.0 vol%. Only under an intentionally extreme condition involving 20 vol% electrolyte and vigorous mixing were transient conductivity spikes of 350–550 μS·cm⁻¹ detected. Thus, within the application-relevant concentration range examined, conductivity monitoring showed limited sensitivity to progressive contamination. These findings concern the response of a commercial low-field conductivity sensor and do not constitute a complete assessment of leakage current, dielectric strength, or full thermal-runaway conditions. Full article

Efficient thermal management is a critical constraint for the performance, safety, and lifetime of electric vehicle (EV) batteries, particularly under transient high-power operation, where conventional dielectric coolants remain limited by the absence of thermal buffering. This Perspective examines PCM–dielectric hybrid coolants as a multiphase electro-thermal-fluid system, in which microencapsulated phase-change materials provide localized latent heat storage within a circulating insulating medium. Rather than proposing a new material concept, the work establishes a system-level engineering framework that links material properties, transport behavior, and electrical constraints to practical implementation. Key challenges, including dispersion stability, capsule durability under coupled stresses, dielectric reliability in heterogeneous media, and rheological limitations, are analyzed alongside quantitative design envelopes and validation pathways. A structured roadmap is presented, spanning multiphysics modeling, accelerated material qualification, system-level testing, and industrial integration, supported by techno-economic and lifecycle considerations. Full article

To overcome the low thermal conductivity and flow channel clogging inherent in traditional phase change materials (PCMs) for immersion cooling, this study develops a novel oil-based phase change emulsion (PCE) integrating high thermal transport with adaptive rheological behavior. A liquid thermal conductivity enhancer was synthesized by modifying epoxidized soybean oil with LiTFSI and blending it with a synthetic ester to form a dielectric base fluid. A mid-to-low-temperature PCM (Span65) was then incorporated via surfactant-free ultrasonic emulsification. The resulting PCE exhibits a tunable phase-change window (25~40 °C) driven by interfacial confinement effects and a multiscale lamellar network. It achieves significantly enhanced thermal conductivity (15% increase over base oil) while maintaining excellent electrical insulation (<10⁻⁹ S/cm). Rheologically, the emulsion transitions from shear-thinning in the solid state to near-Newtonian in the liquid state, optimizing both suspension stability and pumping efficiency. This work establishes a strategy for designing high-performance, safe, and energy-efficient dielectric coolants, offering a robust solution for next-generation electronic and battery thermal management systems. Full article

In recent years, immersion cooling has gained wide interest for thermal management of lithium-ion batteries. Usually, dielectric oils or fluorinated liquid are used as immersion coolants to avert short circuits, but they have low thermal conductivity and high cost. Although water offers superior heat-transfer performance, its poor dielectric property means it cannot be used directly as an immersion coolant. Near full-depth partial immersion (NFDPI) was proposed as a viable alternative, in which water does not contact the tabs of batteries. In this study, an NFDPI experimental system is set up, and the effects of coolant flow rate, discharge rate, and inlet–outlet configuration on thermal management performance are investigated. Since direct observation of the immersion tank’s internal flow is challenging, numerical simulations are conducted to resolve the flow field under various operating conditions. The experimental and simulated results reveal that NFDPI cooling effectively limits the module’s maximum temperature, and the module’s maximum temperature spread is mainly attributed to the cell’s vertical temperature gradient. These findings offer guidance for the practical deployment of water-based NFDPI lithium-ion battery energy storage systems. Full article

As the popularity of electric vehicles (EVs) continues to increase, the need for effective and efficient driveline lubricants and dielectric coolants has become crucial. Commercially used mineral oils or synthetic ester-based coolants, despite performing satisfactorily, are not environmentally friendly. The fatty esters of vegetable oils, after overcoming their shortcomings (like poor oxidative stability, higher viscosity, and pour point) through chemical modification, have recently been used as potential dielectric coolants in transformers. The benefits of natural esters, including a higher flash point, breakdown voltage, dielectric character, thermal conductivity, and most importantly, readily biodegradable nature, have made them a suitable and sustainable substitute for traditional coolants in electric transformers. Based on their excellent performance in transformers, research on their application as dielectric immersion coolants in modern EVs has been emerging in recent years. This review primarily highlights the beneficial aspects of natural esters performing dual functions—cooling as well as lubricating, which is necessary for “wet” e-motors in EVs—through a comparative study with the commercially used mineral and synthetic coolants. The adoption of natural fatty esters of vegetable oils as an immersion cooling fluid is a significant sustainable step for the battery thermal management system (BTMS) of modern EVs considering environmental safety protocols. Continued research and development are necessary to overcome the ongoing challenges and optimize esters for widespread use in the rapidly expanding electric vehicle market. Full article

Cables are critical to the safe and reliable operation of nuclear power plants (NPPs) since they are widely used as a connection medium for various safety-critical equipment. According to research data and operational experience (OPEX), cable materials can degrade with time, resulting in reduced dielectric strength and higher leakage current. Cables may degrade gradually over time under normal service conditions and fail unexpectedly as a result of sudden exposure to harsher environments, such as Secondary Steam Line Breaks (SSLBs), or when required to operate under the severe conditions of a design basis event, such as a Loss-of-Coolant Accident (LOCA). To assess the condition of medium- and low-voltage cables in Canadian nuclear power plants, numerous inspection methods and electrical testing techniques are employed. These techniques include dielectric spectroscopy, polarization/depolarization current analysis, reflectometry, dielectric standby tests, AC partial discharge, and very-low-frequency (VLF) Tan Delta assessments for medium-voltage (MV) cables. While these methods provide precise diagnostic insights, they require cables to be disconnected at both ends and de-energized, posing operational constraints. Consequently, on-line plant cable monitoring has garnered significant interest, particularly for new reactor developments and large-scale NPP refurbishments. This paper provides a comprehensive benchmarking of existing technologies and a state-of-the-art review of modern cable assessment methodologies. It examines commercially available solutions and ongoing research in power testing for low-voltage (LV) and MV cables, with a particular focus on their applicability in nuclear power settings. Full article

Energy storage stations (ESSs) need to be charged and discharged frequently, causing the battery thermal management system (BTMS) to face a great challenge as batteries generate a large amount of heat with a high discharge rate. Supercritical carbon dioxide (SCO₂) is considered a promising coolant because of its favorable properties, including non-flammability, high dielectric strength and low cost for the BTMS. The heat of a battery can be absorbed to a great extent if there is a small temperature rise because as the fluid temperature approaches a pseudo-critical temperature, the specific heat capacity of SCO₂ reaches its peak. In this study, a periodic model of the unit BTMS is established, and a numerical simulation is implemented to investigate the effects of different boundary conditions on the heat dissipation of a battery pack. The flow and heat transfer characteristics of SCO₂ in the liquid cold plate (LCP) of a battery pack with an extreme discharge rate are revealed. The results show that SCO₂ is more preferably used as a coolant compared to water in the same conditions. The maximum temperature and the temperature difference in the battery pack are reduced by 19.22% and 79.9%, and the pressure drop of the LCP is reduced by 40.9%. In addition, the heat transfer characteristic of the LCP is significantly improved upon increasing the mass flow rate. As the operational pressure decreases, the pressure drops of SCO₂ decrease in the LCP. Overall, the maximum temperature and the temperature difference in the battery pack and the pressure drops of the LCP can be effectively controlled by using a coolant made out of SCO₂. This study can provide a reference for the design of BTMSs in the future. Full article

This study aims to assess the compatibility of various e-thermal fluids for immersion cooling in battery electric vehicles through a copper wire resistance corrosion test. The tested fluids include a polyalphaolefin, diester, mineral oil API G-III, transformer oil, and a fully formulated dielectric coolant. The test was conducted at 130 °C for 336 h, and the resistance of the copper wires was monitored in vapor and oil phases. By comparing the resistance variation and analyzing portions of the wires through scanning electron microscopy, it was found that the vapor phase of PAO and diester in one of the tests exhibited significant corrosion, while the dielectric coolant showed minimal corrosive effects, implying better compatibility. These results provide insights into the corrosion behavior and compatibility of the fluids with copper, which are essential for selecting suitable dielectric fluids for immersion cooling applications in electric vehicles. Full article

The lifespan of an electrical transformer, primarily determined by the condition of its solid insulation, is well known under various operating conditions when mineral oil is the coolant in these machines. However, there is a trend toward replacing this oil with biodegradable fluids, especially esters; therefore, an understanding of the ageing of solid insulation with these fluids is essential. Currently available data do not allow for the selection of the best ester among those available on the market, as each study applies different conditions, making it impossible to compare results. Thus, this paper analyses the degradation of Kraft and Thermally Upgraded Kraft papers with the following five most promising commercial esters: sunflower, rapeseed, soybean, palm, and synthetic. The materials underwent accelerated thermal ageing at 130, 150, and 170 °C, and the integrity of the papers was evaluated through their polymerisation degree and the obtaining of the degradation kinetic models. The wide range of materials studied in this work, which were subjected to the same treatments, allows for a comparison of the esters, revealing significant differences in the impact of the alternative fluids. Sunflower, rapeseed, and soybean esters provided the best paper protection, i.e., the degree of polymerisation of Kraft paper in the tests at 150 °C decreased by 71% with these fluids, compared to the 83% reduction with mineral oil, 79% reduction with palm ester, and 75% reduction with synthetic ester. Furthermore, different kinetic models were obtained to predict the degradation; it was concluded that the Emsley model provides the best fit. Additionally, it was found that the behaviour of a dielectric fluid with one type of paper cannot be extrapolated, which is only noticeable in broad-scope studies. Full article

The effects of the coolant pulsation and the plasma aerodynamic actuation (PAA) on the film cooling are herein explored via large eddy simulations. The electrohydrodynamic force derived from the PAA was solved through the phenomenological plasma model. The Strouhal number of the sinusoidal coolant pulsation and the averaged pulsation blowing ratio were 0.25 and 1.0, respectively. Comprehensive analyses were carried out on the time-averaged flow fields, and the results reveal that the pulsed cooling jet might cause a deeper penetration into the crossflow, and this phenomenon could be remarkably mitigated by the downward force of the PAA. Comparing steady film cooling to pulsed film cooling revealed a modest 15.1% reduction in efficiency, while the application of the dielectric barrier discharge plasma actuator (DBDPA) substantially enhanced the pulsed film cooling efficiency by 42.1%. Moreover, the counter-rotating vortex pair (CRVP) was enlarged and lifted off from the wall more poorly due to the coolant pulsation, and the PAA weakened the detrimental lift-off effect and entrainment of the CRVP. Then, the spatial–temporal development of the coherent structures was figured out by the alterations in the centerline temperature, reflecting the formation of the intermittent coherent structures rather than hairpin vortices due to the coolant pulsation, and their size and upcast behaviors were reduced by the PAA; thus, the turbulent integration of the coolant with the crossflow was suppressed fundamentally. Finally, the three-dimensional streamlines confirmed that the coherent structure dynamic behaviors were significantly regulated by the PAA for alleviating the adverse influences of the coolant pulsation. In summary, the PAA can effectively improve the pulsed film cooling efficiency by controlling the spatial–temporal development of the dominant coherent structures. Full article

The current paper aims to present a cooling concept for future centralized platforms of ECUs (Electronic Control Units) from the automotive industry that involves grouping multiple electronic devices into a single system and cooling them with forced convection dielectric coolant. The enhancement consists of replacing the inside air of the module with a dielectric coolant that has a higher thermal conductivity than air and employing an additional prototype system that aids in forced liquid cooling. To meet automotive requirements, the experiments were exposed to an ambient temperature of 85 °C. Temperature measurements on these solutions’ hot spots were compared to those on a thermal paste-only reference electronic module. This study used DFSS (Design for Six Sigma) techniques to determine the ideal pump flow rate, fan air flow rate, and liquid volume in the housing, leading to an optimization in heat dissipation. Finding a trustworthy transfer function that could forecast the impact of the crucial design parameters that had been found was the main goal. The electronics cooled by forced convection coolant improved heat dissipation by up to 60% when compared to the reference module. This demonstrates that the DoE (Design of Experiments) method, which is based on a limited number of measurements, can estimate the behavior of the ECU without the need for a more involved theoretical framework. Full article

Liquid fuel has been the main source of energy in internal combustion engines (ICE) for decades. However, lithium-ion batteries (LIB) have replaced ICE for environmentally friendly vehicles and reducing fossil fuel dependence. This paper focuses on the comparative analysis of battery thermal management system (BTMS) to maintain a working temperature in the range 15–35 °C and prevent thermal runaway and high temperature gradient, consequently increasing LIB lifecycle and performance. The proposed approach is to use biodiesel as the engine feed and coolant. A 3S2P LIB module is simulated using Ansys-Fluent CFD software tool. Four selective dielectric biodiesels are used as coolants, namely palm, karanja, jatropha, and mahua oils. In comparison to the conventional coolants in BTMS, mainly air and 3M Novec, biodiesel fuels have been proven as coolants to maintain LIB temperature within the optimum working range. For instance, the use of palm biodiesel can lightweight the BTMS by 43%, compared with 3M Novec, and likewise maintain BTMS performance. Full article

Electric vehicles (EVs) are incorporated with higher energy density batteries to improve the driving range and performance. The lithium-ion batteries with higher energy density generate a larger amount of heat which deteriorates their efficiency and operating life. The currently commercially employed cooling techniques are not able to achieve the effective thermal management of batteries with increasing energy density. Direct liquid cooling offers enhanced thermal management of battery packs at high discharging rates compared to all other cooling techniques. However, the flow distribution of coolant around the battery module needs to be maintained to achieve the superior performance of direct liquid cooling. The objective of the present work is to investigate the heat transfer characteristics of the lithium-ion battery pack with dielectric fluid immersion cooling for different fin structures. The base structure without fins, circular, rectangular and triangular fin structures are compared for heat transfer characteristics of maximum temperature, temperature difference, average temperature, Nusselt number, pressure drop and performance evaluation criteria (PEC). Furthermore, the heat transfer characteristics are evaluated for various fin dimensions of the best fin structure. The heat transfer characteristics of the battery pack with dielectric fluid immersion cooling according to considered fin structures and dimensions are simulated using ANSYS Fluent commercial code. The results reveal that the symmetrical temperature distribution and temperature uniformity of the battery pack are achieved in the case of all fin structures. The maximum temperature of the battery pack is lower by 2.41%, 2.57% and 4.45% for circular, rectangular, and triangular fin structures, respectively, compared to the base structure. The triangular fin structure shows higher values of Nusselt number and pressure drop with a maximum value of PEC compared to other fin structures. The triangular fin structure is the best fin structure with optimum heat transfer characteristics of the battery pack with dielectric fluid immersion cooling. The heat transfer characteristics of a battery pack with dielectric fluid immersion cooling are further improved for triangular fin structures with a base length -to -height ratio (A/B) of 4.304. The research outputs from the present work could be referred to as a database to commercialize the dielectric fluid immersion cooling for the efficient battery thermal management system at fast and higher charging/discharging rates. Full article

The rapidly growing commercialization of electric vehicles demands higher capacity lithium-ion batteries with higher heat generation which degrades the lifespan and performance of batteries. The currently widely used indirect liquid cooling imposes disadvantages of the higher thermal resistance and coolant leakage which has diverted the attention to the direct liquid cooling for the thermal management of batteries. The present study conducts the experimental investigation on discharge and heat transfer characteristics of lithium-ion battery with direct liquid cooling for the thermal management. The 18,650 lithium-ion cylindrical battery pack is immersed symmetrically in dielectric fluid. The discharge voltage and capacity, maximum temperature, temperature difference, average temperature, heat absorbed, and heat transfer coefficient are investigated under various conditions of discharge rates, inlet temperatures, and volume flow rates of coolant. The operating voltage and discharge capacity are decreasing with increase in the volume flow rate and decrease in the inlet temperature for all discharge rates. At the higher discharge rate of 4C, the lowest battery maximum temperatures of 60.2 °C and 44.6 °C and the highest heat transfer coefficients of 2884.25 W/m²-K and 2290.19 W/m²-K are reported for the highest volume flow rate of 1000 mLPM and the lowest inlet temperature of 15 °C, respectively. Full article

Amidst the new techniques facing the improvement of cooling and insulating efficiency and the design of electric transformers, constrained by the current technologies, one of the more promising is the substitution of traditional dielectric oils for nanofluids. Research on nanofluids for their application in transformers as a coolant and dielectric medium have been performed during the last two decades and continue today. This review tries to collect and analyze the available information in this field and to offer it already dissected to researchers, focusing on the preparation methods and how nanoparticles affect the main properties of the base fluids. Here we also addressed the influence of different parameters as particle characteristics or environmental conditions in nanofluids performance, the evolution with time of the measured properties, or the neighboring relationship of nanofluids with other transformer components. In this sense, the most reviewed articles reflect enhancements of thermal conductivity or dielectric strength, as well as an improvement of time evolution of these properties, with respect to those that are found in base fluids, and, also, a better interaction between these nanofluids and dielectric cellulosics. Thus, the use of dielectric nanofluids in transformers may allow these machines to work safer or over their design parameters, reducing the risk of failure of the electrical networks and enhancing their life expectancy. Nevertheless, these advantages will not be useful unless a proper stability of nanofluids is ensured, which is achieved in a small part of revised articles. A compendium of the preparation methodology with this aim is proposed, to be checked in future works. Full article