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Research on the thermal management performance of battery module with heat pipe in the full-scenarios and multiple dimensions

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APPLIED THERMAL ENGINEERING 2025年 263卷

作者： Li, Jingjing Chen, Meng Zeng, Xiaohua Song, Dafeng Jilin Univ Natl Key Lab Automot Chassis Integrat & Bion Changchun 130025 Peoples R China Jilin Univ Coll Automot Engn Changchun 130025 Peoples R China Northeast Forestry Univ Coll Mech & Elect Engn Harbin 150040 Peoples R China

To solve the continuous high temperature, and local overheating and further improve the temperature uniformity of battery, in common application scenarios, a novel closed-loop pulsating heat pipe (CLPHP) is designed, which uses titanium dioxide (TiO2) metal oxide nanofluids as a working fluid to significantly improve heat transfer performance. And thermal management system (TMS) is proposed by examining the characteristics of the pulsating heat pipe's heat transfer and the large-surface cooling of the aluminum soaking plate. On this basis, the thermal management performance in full-scenarios and multi-dimensions is tested. The performance response characteristics and the thermal-electrical performance changes and interaction relationships of the battery module are quantified and revealed. It can be concluded from the relevant experimental results that from the thermal performance, CLPHP with forced air has the strongest emergency thermal management ability, and the maximum temperature suppression rate exceeds 30 %, even at the end of constant power discharge, it can keep the temperature difference less than 4.3 degrees C . CLPHP with forced air meets the dual requirements of maximum temperature and temperature uniformity of the battery module. From the thermal performance, at the end of constant current discharge, the voltage drop corresponding to CLPHP with forced air cooling is the largest, and the voltage drop can reach 0.55 V and 0.50 Vat different discharge rates. However, at the end of constant power discharge, a difference exists amongst the systems, the battery voltage corresponding to forced air and natural air changes sharply. The above results prove that CLPHP with forced air can improve the thermal performance of the battery module and optimize its electrical performance.

关键词： battery module Charge and discharge scenarios Thermal management schemes Performance response Action mechanism

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Numerical simulation study of thermal runaway jet fire characteristics of forced air-cooled cylindrical battery module

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CASE STUDIES IN THERMAL ENGINEERING 2025年 66卷

作者： Wu, Xiantong Hu, Yanxin Wu, Tingting Zhuo, Ziqi Qiu, Huihe Zhu, Yishun Li, Xingyu Tang, Run Guangdong Univ Technol Guangzhou 510006 Peoples R China Hong Kong Univ Sci & Technol Guangzhou Thrust Sustainable Energy & Environm Guangzhou 510000 Peoples R China Guangdong Power Grid Co Ltd Guangzhou Power Supply Bur Guangzhou 510000 Peoples R China

To elucidate the spread characteristics of the thermal runaway jet flame in the forced-air-cooled 18650 battery module, a three-dimensional thermal runaway jet fire model is constructed. The process of thermal runaway jet gas passing through the safety valve is modeled as isentropic flow, with the velocity inlet boundary applied to the safety valve of the battery. The combustion of the thermal runaway jet gas is simulated using the Eddy Dissipation model within the volume reaction module. Results indicate that when the second cell (cell 2) undergoes thermal runaway jet combustion, the maximum average temperature in the fluid domain of the air-cooled module rises to 1206.41K. In cells aligned in the same row, those nearer to the downstream end initiate jet fires, resulting in a lower maximum average temperature in the fluid domain. Carbon monoxide generated during thermal runaway is predominantly distributed in the upper section of the aircooled module, with a maximum concentration of 16787 ppm, posing significant safety risks.

关键词： battery module Forced cooling Thermal runaway Jet fire Ansys fluent

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Numerical simulation and experimental study of a novel emergency cooling system for thermal runaway propagation of power battery module

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APPLIED THERMAL ENGINEERING 2025年 272卷

作者： Jia, Shuyuan Li, Nian Shuang, Liu Zhang, Xu Tang, Fujing Wu, JieYu Xu, Xiangguo Dongfeng Motor Corp Res & Dev Inst Wuhan 430101 Peoples R China Zhejiang Univ Inst Refrigerat & Cryogen Key Lab Refrigerat & Cryogen Technol Zhejiang Prov 38 Zheda Rd Hangzhou Peoples R China Zhejiang Univ Ningbo Res Inst Ningbo 315100 Peoples R China Xiangyang Da An Automobile Ctr Corp Ltd Xiangyang 441004 Peoples R China

The thermal runaway process of large capacity Lithium-ion ternary battery is quite severe, so effective suppression of thermal runaway is crucial for battery safety. This article explores an innovative approach to controlling thermal runaway in ternary lithium batteries through a spray cooling method with a refrigerant-based cooling medium that integrates vortex tube gas cooling. By directly injecting refrigerant into the battery module, this method rapidly extinguishes fires and cools overheated battery cells during thermal runaway events. module-level experiments and numerical simulations were conducted to evaluate the performance of this coupled cooling strategy. Specifically, the study analyzed the effects of two refrigerants and three distinct injection modes on the emergency cooling efficiency. The result shows that the cooling medium spray significantly reduce the temperature of thermally runaway cells and has obvious thermal inhibition effect on the adjacent battery. Among them, the cooling performance of intermittent spraying with shorter intervals surpasses that of continuous spraying. With an inlet temperature of 0 degrees C for the R134a refrigerant, the cell temperature decreases at a relatively faster rate with intermittent spraying. The fire extinguishing test of the emergency cooling system was carried out, and it was found that the flame duration of CO2 vortex tube cooling with R227ea spray cooling was only 5 s, and the heat spread time of the battery module was tripled after spraying for 20 s. The emergency cooling of battery has important reference significance for the design of high-capacity ternary lithium battery. This work provides valuable insights for designing emergency cooling systems for high-capacity lithium-ion ternary batteries, contributing to improved safety and thermal management strategies.

关键词： Thermal runaway Vortex tube battery module Control strategy Lithium-ion ternary battery High-capacity

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Comprehensive understanding of the effects of imbalanced cell via battery module tests for further usage of cycled batteries

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JOURNAL OF POWER SOURCES 2025年 631卷

作者： Oh, Jimin Lee, Miyoung Ko, Eunjin Kim, Kwang Man Kim, Jonghoon Kyungpook Natl Univ Adv Inst Sci & Technol Dept Smart Mobil Engn 80 Daehak Ro Daegu 41566 South Korea Elect & Telecommun Res Inst ICT Creat Res Lab Daejeon 34129 South Korea Chungnam Natl Univ Dept Elect Engn Energy Storage Convers Lab 99 Daehak Ro Daejeon South Korea

In this study, a comprehensive understanding on the battery module with an imbalanced cell is assessed in terms of its electrical, thermal, and electrochemical effects. By conducting electrical and thermal analysis using a 2 x 2 battery module for electric vehicle battery pack representative unit, normally combined with series and parallel, we observe property variations at the charge and discharge voltage profiles, as well as impacts of distinct reactions by series and parallel connections. The series-connected cell configuration on the module corresponds to the voltage variance, while the parallelconnected one induces temperature disparity. This comprehensive examination through two modules (model vs. reference module) is conducted to ascertain whether the outcomes of the electrical and thermal property analyses correspond to the internal chemical condition and configuration of the battery when the imbalanced modules connect in series and parallel are in operation. Our findings reveal a significant relationship between the electrical imbalances in each cell, the thermal consequences on the battery module, and the electrochemical impacts on the electrodes. However, we also reveal that there are normal cells among battery module when degraded with imbalances. Based on those results, our research provides economical information for the process of repurposing battery electrodes from imbalanced battery modules that will be appeared after cycled (or degraded) electric vehicle battery, which is crucial for improving the efficiency of an imbalanced batteries.

关键词： Chemically imbalanced cell Electric and thermal analysis Electrochemical analysis battery module Electrode re-use

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Effect of immersion cooling design optimization on thermal management for lithium battery module

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APPLIED THERMAL ENGINEERING 2025年 272卷

作者： Song, Yuchen Wang, Zhi Jia, Deyuan Yuan, Diping Chang, Yi Zheng, Xulong Zhang, Shengtao China Univ Min & Technol Shenzhen Res Inst Shenzhen Peoples R China China Univ Min & Technol Sch Safety Engn Xuzhou Peoples R China Univ Sci & Technol China State Key Lab Fire Sci Hefei Peoples R China China Univ Min & Technol Key Lab Gas & Fire Control Coal Mines Xuzhou Peoples R China China Univ Min & Technol State Key Lab Coal Mine Disaster Prevent & Control Xuzhou Peoples R China GAC AION NEW ENERGY AUTOMOBILE CO LTD Guangzhou Peoples R China

Immersion cooling has attracted significant attention due to its excellent ability to exchange heat through direct contact with the battery surface. The design of the channels within the immersion system plays a crucial role in optimizing cooling efficiency. Therefore, this study explores various immersion system designs, focusing on parameters such as flow rate, inlet arrangements, and channel structures, in order to identify more effective methods for immersion cooling. The simulation results indicate that a flow rate of 1.5 x 10-2 L.s-1 provides a better balance between cooling performance and power consumption. The single inlet design offers superior cooling and lower power consumption compared to the double inlet, with a heat absorption capacity of up to 81.5 kJ. Regarding the channel structure, the baffle arrangements on both sides of the channel or on the outlet side are more effective in thermal management. Among these, the baffle arrangement on the outlet side uses fewer baffles, making it more cost effective. Specifically, it can maintain a temperature of 31.45 degrees C with a temperature difference of 6.16 degrees C, while absorbing 83.2 kJ of heat. In addition, the cooling mechanism of immersion thermal management is revealed from a turbulence perspective. The findings of this study provide a theoretical foundation and offer improved design alternatives for the immersion thermal management of battery module.

关键词： battery module Thermal management Immersion cooling Heat transfer

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battery parameter identification method of a battery module based on a multi-physical measurement system

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JOURNAL OF ENERGY STORAGE 2024年 80卷

作者： Li, Xiaoyu Chen, Fengyi Lin, Shaohong Huang, Zhijia Tian, Yong Tian, Jindong Shenzhen Univ State Key Lab Radio Frequency Heterogeneous Integr Shenzhen 518060 Peoples R China Beijing Inst Technol Sch Mech Engn Natl Engn Lab Elect Vehicles Beijing 100081 Peoples R China Shenzhen Univ Coll Phys & Optoelect Engn Key Lab Optoelect Devices & Syst Minist Educ & Guangdong Prov Shenzhen 518060 Peoples R China

The secondary utilization of retired electric vehicle batteries is beneficial for improving resource utilization efficiency. Capacity and internal resistance are battery parameters that can reflect the battery state. To identify the parameters of a single battery in a battery module, it is usually necessary to disassemble the battery module. The process is complex, time-consuming, and unsafe. In this paper, a battery parameter identification method without disassembling the battery module is developed based on a multi-physical measurement system. First, a multi-physical electrical-thermal-spatial measurement system is constructed to measure the physical parameters of the battery module during charging and discharging. Then, the electrical model and the thermal model are developed. To obtain the capacity and internal resistance of each cell within the battery module, a battery parameter identification model is established with temperature and total battery current as input parameters and battery capacity and internal resistance as output parameters. Batteries with different capacities and internal resistances are connected in series and parallel to simulate retired battery modules for electric vehicles. The battery parameters are identified using the method presented in this paper. According to the experiments, the relative errors of parameter identification for battery capacity and internal resistance are both within 9 %. This method can improve the efficiency of the battery screening process as well as the reliability of the battery system.

关键词： Multiphysics Data fusion battery module Modelling Parameter identification

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Adaptive engineering-assisted deep learning for battery module health monitoring across dynamic operations

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ENERGY 2025年 322卷

作者： Tang, Aihua Xu, Yuchen Tian, Jinpeng Zou, Hang Liu, Kailong Yu, Quanqing Chongqing Univ Technol Key Lab Adv Mfg Technol Automobile Parts Minist Educ Chongqing 400054 Peoples R China Hong Kong Polytech Univ Dept Elect & Elect Engn Hong Kong 999077 Peoples R China Hong Kong Polytech Univ Res Ctr Grid Modernisat Hong Kong 999077 Peoples R China Chongqing Univ Technol Informat Ctr Minist Educ Chongqing 400054 Peoples R China Shandong Univ Sch Control Sci & Engn Jinan 250100 Shandong Peoples R China Harbin Inst Technol Sch Automot Engn Weihai 264209 Peoples R China

Accurately assessing the health degradation of battery modules is crucial for the stable operation of electric vehicles. However, most existing methods rely on ideal constant current charging data, which is not suitable for real-world dynamic conditions. To address this issue, this study proposes an adaptive engineering-assisted deep learning framework for estimating the state of health of battery modules under different dynamic conditions. The method comprises an adaptive voltage corrector with built-in Lowess smoothing, voltage descending, and correlation alignment components, along with a specifically developed convolutional neural network. Initially, 10 min discharge segments under different dynamic conditions are inputted into the adaptive voltage corrector and sequentially corrected by the three built-in components. The corrected voltages have similar degradation trends and smaller data divergence, which helps deep learning to extract potentially similar features under different dynamic conditions. Subsequently, a convolutional neural network is developed to establish a robust and reliable mapping between the corrected voltages and state of health. Finally, cross-validation results across four conditions show that the estimation results maintain an root mean square error around 1.0 % using 10-min discharge segments. The proposed method is expected to help deep learning process complex real-world data by introducing adaptive engineering.

关键词： battery module State of health Dynamic operations Adaptive engineering Deep learning

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Performance response analysis of battery module with nanofluids pulsating heat pipes under normal and high-temperature charging scenarios

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APPLIED THERMAL ENGINEERING 2024年 257卷

作者： Li, Jingjing Qiao, Lulu Lv, Wenjie Zeng, Xiaohua Chen, Meng Jilin Univ State Key Lab Automot Simulat & Control Changchun 130025 Peoples R China Jilin Univ Coll Automot Engn Changchun 130025 Peoples R China Northeast Forestry Univ Sch Civil Engn & Transportat Harbin 150040 Peoples R China Northeast Forestry Univ Coll Mech & Elect Engn Harbin 150040 Peoples R China

For the wide application scenario of "normal and high-temperature environment, high current charging" of electric vehicles (Evs), there is local overheating, continuous high temperature, and poor temperature uniformity of the power battery, which will lead to potential safety problems such as overheating fire, accelerated aging and overcharge damage. This manuscript proposes a novel battery thermal management system (TMS) with a closed- loop pulsating heat pipe (CLPHP). On this basis, the thermal-electric performance response characteristic tests of the battery module are carried out, and the interaction relationship of the thermal-electrical performance of the battery module is revealed and quantified. Finally, the evaluation method considering electrical performance is proposed. The results show that in terms of thermal performance, the maximum temperature and temperature rise of the battery module with CLPHP TMS is greatly inhibited, and the temperature rise inhibition ratio is as high as 56.67 % and 80.00 %. The temperature difference of the battery module does not exceed 1.0 degrees C. In terms of electrical performance, the battery module with CLPHP TMS has a weak trend of the ante-displacement of charge voltage, the charging capacity is closer to the normal capacity, and the charging capacity ratio fluctuates around 100.00 %. Obviously, the battery module with CLPHP TMS has more healthy and reasonable electrical performance. What's more, the CLPHP TMS has effectively taken into account the thermal and electrical performance and realized the maximum thermal management efficiency of the system. With the completion of this study, which greatly meets the harsh requirements of the high-energy-density battery module the temperature difference of the battery does not exceed 1.0-2.0 degrees C and makes up for the shortcomings of the traditional thermal management scheme in this respect. The proposed effectiveness evaluation method realizes the rapid evaluation of dif

关键词： battery module Charging scenario TiO2-CLPHP Thermal-electrical performance Comprehensive evaluation

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Optimization of an immersion cooling 46.5 kW/46.5 kWh battery module using flow resistance network shortcut method

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JOURNAL OF ENERGY STORAGE 2024年 103卷

作者： Shi, Qianlei Liu, Qian Liu, Yingying Yao, Xiaole Zhu, Xiaoqing Ju, Xing Xu, Chao North China Elect Power Univ Beijing Lab New Energy Storage Technol Beijing 102206 Peoples R China

Immersion cooling technology the most important thermal management technology. Flow organization is the crucial strategy to improve the temperature uniformity. The flow resistance network shortcut method, which is efficient for the design of fluid flow, is also a potentially appropriate method for immersion cooling optimization. This study proved its applicability in a 46.5 kW/46.5 kWh battery module thermal management design. The flow resistance network can solve the velocity field in seconds, and the maximum relative error of the solution is only 6 %. Results show that, root mean square error (RMSE) of the flow rate between the mini-channels, which indicates the flow non-uniformity, are respectively 0.11 and 0.30 for Z-flow and U-flow at a volume flow rate of 32 L/min. To improve the uniformity, the randomized controlled trial (RCT) is introduced in the design of a uniform distribution of flow structures by the battery topology arrangement. The lowest RMSE of the Z-flow and U-flow reduces to 0.04 and 0.068, respectively. Then, we establish the optimized structure design and import it into Ansys Fluent. The temperature uniformity for Z-type flow and U-type flow is improved by 16.45 % and 56.16 %, respectively. The abovementioned method provides an efficient optimization for large-scale battery thermal management system (BTMS) flow structure design.

关键词： battery module battery thermal management system Immersion cooling Flow resistance network Reduce order model

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Experimental study on the performance of power battery module heating management under a low-temperatures charging scenario

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INTERNATIONAL JOURNAL OF HEAT AND MASS TRANSFER 2024年 225卷

作者： Zeng, Xiaohua Li, Jingjing Qiao, Lulu Chen, Meng Jilin Univ Coll Automot Engn Changchun 130025 Peoples R China Jilin Univ State Key Lab Automot Simulat & Control Changchun 130025 Peoples R China Northeast Forestry Univ Coll Mech & Elect Engn Harbin 150040 Peoples R China

To effectively solve the problem that the capacity of lithium power batteries decreases significantly and is prone to irreversible damage under low-temperature charge and discharge scenarios, which seriously affects the driving range, cycle life and service safety of electric vehicles (EVs). In this paper, a low-temperatures thermal management system of pulsating heat pipes with ethanol as the base fluids and TiO2 nanofluids as the working fluids (TiO2-CLPHP TMS) is constructed. On this basis, the thermal performance analysis of TiO2 nanofluids pulsating heat pipes (TiO2-CLPHP) is carried out under different volume concentrations (0 %, 0.5 %, 1.0 %, 2.0 %, 4.0 %, and 8.0 %) and different fluid filling rates (30 %, 50 %, 70 %, and 90 %) in a low-temperature environment. Aiming at the low-temperatures charging scenario of the battery module, the performance test of the TiO2-CLPHP TMS for the battery module heating management is carried out under different low-temperature environments (-5 degrees C, -15 degrees C, and -25 degrees C) and different charging rates (0.3C, 0.5C, 0.7C, and 1.0C). The experimental results show that TiO2-CLPHP with fluids filling rate of 50.00 % and TiO2 nanofluids concentration of 2.00 % has good performance in start-up and heat transfer, and can optimize the thermal performance of TiO2-CLPHP. Meanwhile, TiO2-CLPHP TMS can ensure that the battery module has superior thermal performance. the battery module can be charged within the allowed temperature range (greater than 0 degrees C). under different low temperature environments (-5 degrees C, -15 degrees C, and -25 degrees C), the temperature of the battery module is basically maintained at 3.30 degrees C, 8.00 degrees C and 16.00 degrees C. The temperature difference between different areas of the battery module is within the allowable temperature difference range of 5 degrees C, which reduces the adverse effects of the battery aging caused by low-temperature charging and uneven temperature.

关键词： battery module Low temperature environment TiO2-CLPHP Heating management Performance analysis

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