Two-phase cooling system for electric vehicles’ battery

Abstract The objective of this research project is to design an innovative cooling system for effectively managing the thermal conditions of batteries in electric vehicles. Electric vehicles commonly utilize Lithium-Ion cells as their power source. Despite significant advancements in Lithium-Ion technology from an electrochemical standpoint, the thermal management of these batteries remains a formidable challenge. This is primarily due to the demanding operational conditions that Lithium-Ion cells face during battery discharge, motion, and charging. The power supply unit in electric vehicles often demands high power outputs within short durations, leading to the generation of substantial heat by the batteries. This elevated working temperature poses a risk of decreased battery performance or even malfunction. Therefore, an efficient battery thermal management system is essential to optimize the performance of the batteries. In our research project, we propose and investigate a cooling system that is directly integrated into the power supply unit. Our study introduces an innovative thermal management system that combines two-phase direct liquid cooling with pulsating heat pipes. This system provides a compelling solution by combining high thermal efficiency, passive operation, and cost-effectiveness. Within this configuration, batteries are immersed in a low-boiling dielectric fluid contained in a Plexiglas container, facilitating efficient heat exchange. Simultaneously, the pulsating heat pipe operates to manage heat spikes by promoting vapor recondensation, thereby maintaining safe operational temperatures. The proposed battery thermal management system has demonstrated remarkable efficiency, ensuring that battery temperatures remain within the recommended range even under high load conditions. A notable advantage of this cooling system is its complete passivity, eliminating the need for energy-consuming coolant circulation.