Heat Pipe Integrated Cooling System of 4680 Lithium–Ion Battery for Electric Vehicles

This study investigates a novel heat pipe integrated cooling system designed for thermal management of Tesla’s 4680 cylindrical lithium–ion batteries in electric vehicles (EVs). Through a comprehensive approach combining experimental analysis, 1-D AMESim simulations, and 3-D Computational Fluid Dynamics (CFD) modeling, the thermal performance of various wick structures and working fluid filling ratios was evaluated. The experimental setup utilized a triangular prism chamber housing three surrogate heater blocks to replicate the heat generation of 4680 cells under 1C, 2C, and 3C discharge rates. Results demonstrated that a blended fabric wick with a crown-shaped design (Wick 5) at a 30–40% filling ratio achieved the lowest maximum temperature (Tmax of 47.0°C), minimal surface temperature deviation (ΔTsurface of 2.8°C), and optimal thermal resistance (Rth of 0.27°C/W) under 85 W heat input. CFD simulations validated experimental findings, confirming stable evaporation–condensation circulation at a 40% filling ratio, while identifying thermal limits at high heat loads (155 W). The proposed hybrid battery thermal management system (BTMS) offers significant potential for enhancing the performance and safety of high-energy density EV batteries. This research provides a foundation for optimizing thermal management in next-generation electric vehicles.