Thermal management system of e-vehicle Li-ion battery modules: A comprehensive review

Year 2024, Volume: 10 Issue: 6, 1679 - 1697, 19.11.2024

Ajoy Debbarma

Abstract

Electric vehicles have the potential to address humanity’s issues of environmental deterioration and energy scarcity. Electric vehicles frequently use lithium-ion batteries as their power source. The heat is generated when the batteries are subjected to high-power charging and discharging loads. This results in a considerable loss in battery life and raises the possibility of a battery explosion. As a result, quick heat dissipation from the cells is required to ensure safe operation and longer battery life cycles. Air cooling is the most basic type of thermal management; yet, due to its poor thermal conductivity, it has its restrictions. Liquid cooling agents are superior to air cooling systems in terms of thermal control. Liquid cooling, on the other hand, added complexity to the working system, increased operating costs, and increased total system weight. A similar problem might be seen when applying the heat pipe concept of cooling systems. PCM provides several advantages over above mentioned three cooling technologies, but it also has a limited heat storage capacity and poor thermal conductivity. As a result, a hybrid BTMS paradigm emerges. However, research on hybrid techniques is still insufficient. To make effective hybrid BTMS technology, efforts are being undertaken, and earlier research on the hybrid is also summarized in this study.

Keywords

Battery Thermal Management System, Battery Thermal Runaway, Cooling Enhancement Techniques, Hybrid Mode of Cooling Techniques, Single Cooling Techniques

References

• [1] Kitoh K, Nemoto H. 100 Wh large size Li-ion batteries and safety tests. J Power Sources 1999;81:887–890. [CrossRef]
• [2] Tong W, Somasundaram K, Birgersson E, Mujumdar AS, Yap C. Thermo-electrochemical model for forced convection air cooling of a lithium-ion battery module. Appl Therm Engineer 2016;99:672–682. [CrossRef]
• [3] Rangappa R, Rajoo S. Effect of thermo-physical properties of cooling mass on hybrid cooling for lithium-ion battery pack using design of experiments. Int J Energy Environ Engineer 2019;10:67–83. [CrossRef]
• [4] Zhao R, Liu J, Gu J, Zhai L, Ma F. Experimental study of a direct evaporative cooling approach for Li‐ion battery thermal management. Int J Energy Res 2020;44:6660–6673. [CrossRef]
• [5] Ling Z, Chen J, Fang X, Zhang Z, Xu T, Gao X, et al. Experimental and numerical investigation of the application of phase change materials in a simulative power batteries thermal management system. Appl Energy 2014;121:104–113. [CrossRef]
• [6] Li WQ, Qu ZG, He YL, Tao YB. Experimental study of a passive thermal management system for high-powered lithium ion batteries using porous metal foam saturated with phase change materials. J Power Sources 2014;255:9–15. [CrossRef]
• [7] Wang Z, Zhang Z, Jia L, Yang L. Paraffin and paraffin/aluminum foam composite phase change material heat storage experimental study based on thermal management of Li-ion battery. Appl Therm Engineer 2015;78:428–436. [CrossRef]
• [8] Lu Z, Meng XZ, Wei LC, Hu WY, Zhang LY, Jin LW. Thermal management of densely-packed EV battery with forced air cooling strategies. Energy Procedia 2016;88:682–688. [CrossRef]
• [9] Saw LH, Ye Y, Tay AA, Chong WT, Kuan SH, Yew MC. Computational fluid dynamic and thermal analysis of Lithium-ion battery pack with air cooling. Appl Energy 2016;177:783–792. [CrossRef]
• [10] Pesaran AA. Battery thermal models for hybrid vehicle simulations. J Power Sources 2002;110:377–382. [CrossRef]
• [11] Giuliano MR, Prasad AK, Advani SG. Experimental study of an air-cooled thermal management system for high capacity lithium–titanate batteries. J Power Sources 2012;216:345–352. [CrossRef]
• [12] Yang XH, Tan SC, Liu J. Thermal management of Li-ion battery with liquid metal. Energy Conver Manage 2016;117:577–585. [CrossRef]
• [13] Azizi Y, Sadrameli SM. Thermal management of a LiFePO4 battery pack at high temperature environment using a composite of phase change materials and aluminum wire mesh plates. Energy Conver Manage 2016;128:294–302. [CrossRef]
• [14] Chen D, Jiang J, Kim GH, Yang C, Pesaran A. Comparison of different cooling methods for lithium ion battery cells. Appl Therm Engineer 2016;94:846–854. [CrossRef]
• [15] Zhao J, Lv P, Rao Z. Experimental study on the thermal management performance of phase change material coupled with heat pipe for cylindrical power battery pack. Exp Therm Fluid Sci 2017;82:182–188. [CrossRef]
• [16] Kizilel R, Sabbah R, Selman JR, Al-Hallaj S. An alternative cooling system to enhance the safety of Li-ion battery packs. J Power Sources 2009;194:1105–1112. [CrossRef]
• [17] Chen M, Zhang S, Wang G, Weng J, Ouyang D, Wu X, et al. Experimental analysis on the thermal management of lithium-ion batteries based on phase change materials. Appl Sci 2020;10:7354. [CrossRef]
• [18] Javani N, Dincer I, Naterer GF. Numerical modeling of submodule heat transfer with phase change material for thermal management of electric vehicle battery packs. J Therm Sci Engineer Appl 2015;7:031005. [CrossRef]
• [19] Nayak KC, Saha SK, Srinivasan K, Dutta P. A numerical model for heat sinks with phase change materials and thermal conductivity enhancers. Int J Heat Mass Transf 2006;49:1833–1844. [CrossRef]
• [20] Weng J, Yang X, Zhang G, Ouyang D, Chen M, Wang J. Optimization of the detailed factors in a phase-change-material module for battery thermal management. Int J Heat Mass Transf 2019;138:126–134. [CrossRef]
• [21] Javani N, Dincer I, Naterer GF, Yilbas BS. Heat transfer and thermal management with PCMs in a Li-ion battery cell for electric vehicles. Int J Heat Mass Transf 2014;72:690–703. [CrossRef]
• [22] Zhang J, Li X, He F, He J, Zhong Z, Zhang G. Experimental investigation on thermal management of electric vehicle battery module with paraffin/expanded graphite composite phase change material. Int J Photoenergy 2017;2017:2929473. [CrossRef]
• [23] Hussain A, Tso CY, Chao CY. Experimental investigation of a passive thermal management system for high-powered lithium ion batteries using nickel foam-paraffin composite. Energy 2016;115:209–218. [CrossRef]
• [24] Mohammadian SK, Rassoulinejad-Mousavi SM, Zhang Y. Thermal management improvement of an air-cooled high-power lithium-ion battery by embedding metal foam. J Power Sources 2015;296:305–313. [CrossRef]
• [25] Joshi V, Rathod MK. Thermal performance augmentation of metal foam infused phase change material using a partial filling strategy: An evaluation for fill height ratio and porosity. Appl Energy 2019;253:113621. [CrossRef]
• [26] Baby R, Balaji C. Experimental investigations on thermal performance enhancement and effect of orientation on porous matrix filled PCM based heat sink. Int Comm Heat Mass Transf 2013;46:27–30. [CrossRef]
• [27] Dinesh BVS, Bhattacharya A. Comparison of energy absorption characteristics of PCM-metal foam systems with different pore size distributions. J Energy Storage 2020;28:101190. [CrossRef]
• [28] Jilte R, Afzal A, Panchal S. A novel battery thermal management system using nano-enhanced phase change materials. Energy 2021;219:119564. [CrossRef]
• [29] Ye Y, Saw LH, Shi Y, Tay AA. Numerical analyses on optimizing a heat pipe thermal management system for lithium-ion batteries during fast charging. Appl Therm Engineer 2015;86:281–291. [CrossRef]
• [30] Ye Y, Shi Y, Saw LH, Tay AA. Performance assessment and optimization of a heat pipe thermal management system for fast charging lithium ion battery packs. Int J Heat Mass Transf 2016;92:893–903. [CrossRef]
• [31] Putra N, Ariantara B, Pamungkas RA. Experimental investigation on performance of lithium-ion battery thermal management system using flat plate loop heat pipe for electric vehicle application. Appl Therm Engineer 2016;99:784–789. [CrossRef]
• [32] Liang J, Gan Y, Li Y, Tan M, Wang J. Thermal and electrochemical performance of a serially connected battery module using a heat pipe-based thermal management system under different coolant temperatures. Energy 2019;189:116233. [CrossRef]
• [33] Dan D, Yao C, Zhang Y, Zhang H, Zeng Z, Xu X. Dynamic thermal behavior of micro heat pipe array-air cooling battery thermal management system based on thermal network model. Appl Therm Engineer 2019;162:114183. [CrossRef]
• [34] Wang J, Gan Y, Liang J, Tan M, Li Y. Sensitivity analysis of factors influencing a heat pipe-based thermal management system for a battery module with cylindrical cells. Appl Therm Engineer 2019;151:475–485. [CrossRef]
• [35] Behi H, Karimi D, Behi M, Ghanbarpour M, Jaguemont J, Sokkeh MA, et al. A new concept of thermal management system in Li-ion battery using air cooling and heat pipe for electric vehicles. Appl Therm Engineer 2020;174:115280. [CrossRef]
• [36] Behi H, Behi M, Karimi D, Jaguemont J, Ghanbarpour M, Behnia M, et al. Heat pipe air-cooled thermal management system for lithium-ion batteries: High power applications. Appl Therm Engineer 2021;183:116240. [CrossRef]
• [37] Gan Y, Wang J, Liang J, Huang Z, Hu M. Development of thermal equivalent circuit model of heat pipe-based thermal management system for a battery module with cylindrical cells. Appl Therm Engineer 2020;164:114523. [CrossRef]
• [38] Jin X, Duan X, Jiang W, Wang Y, Zou Y, Lei W, et al. Structural design of a composite board/heat pipe based on the coupled electro-chemical-thermal model in battery thermal management system. Energy 2021;216:119234. [CrossRef]
• [39] Ren R, Zhao Y, Diao Y, Liang L, Jing H. Active air-cooling thermal management system based on U-shaped micro heat pipe array for lithium-ion battery. J Power Sources 2021;507:230314. [CrossRef]
• [40] Alihosseini A, Shafaee M. Experimental study and numerical simulation of a Lithium-ion battery thermal management system using a heat pipe. J Energy Storage 2021;39:102616. [CrossRef]
• [41] Jouhara H, Serey N, Khordehgah N, Bennett R, Almahmoud S, Lester SP. Investigation, development and experimental analyses of a heat pipe based battery thermal management system. Int J Therm Fluids 2020;1:100004. [CrossRef]
• [42] Lei S, Shi Y, Chen G. Heat-pipe based spray-cooling thermal management system for lithium-ion battery: Experimental study and optimization. Int J Heat Mass Transf 2020;163:120494. [CrossRef]
• [43] Ren R, Zhao Y, Diao Y, Liang L. Experimental study on preheating thermal management system for lithium-ion battery based on U-shaped micro heat pipe array. Energy 2022;253:124178. [CrossRef]
• [44] Yao M, Gan Y, Liang J, Dong D, Ma L, Liu J, et al. Performance simulation of a heat pipe and refrigerant-based lithium-ion battery thermal management system coupled with electric vehicle air-conditioning. Appl Therm Engineer 2021;191:116878. [CrossRef]
• [45] Buidin TIC, Mariasiu F. Battery thermal management systems: Current status and design approach of cooling technologies. Energies 2021;14:4879. [CrossRef]
• [46] Yaqzan M, Rafat Y, Abdullah S, Alam MS. Thermal management solutions of lithium-ion energy storage batteries for xev deployment in north india. In: Pillai RK, Seethapathy R, Khaparde SA, Chaudhuri S, editors. ISGW 2017: Compendium of Technical Papers. Singapore: Springer; 2018. pp. 179–191. [CrossRef]
• [47] Wei Y, Agelin-Chaab M. Experimental investigation of a novel hybrid cooling method for lithium-ion batteries. Appl Therm Engineer 2018;136:375–387. [CrossRef]
• [48] Saw LH, King YJ, Yew MC, Ng TC, Chong WT, Pambudi NA. Feasibility study of mist cooling for lithium-ion battery. Energy Proc 2017;142:2592–2597. [CrossRef]
• [49] Saw LH, Poon HM, San Thiam H, Cai Z, Chong WT, Pambudi NA, et al. Novel thermal management system using mist cooling for lithium-ion battery packs. Appl Energy 2018;223:146–158. [CrossRef]
• [50] Yang Y, Yang L, Du X, Yang Y. Pre-cooling of air by water spray evaporation to improve thermal performance of lithium battery pack. Appl Therm Engineer 2019;163:114401. [CrossRef]
• [51] Huang Y, Wu Y, Liu B. Experimental investigation into the use of emergency spray on suppression of battery thermal runaway. J Energy Storage 2021;38:102546. [CrossRef]
• [52] Liu T, Tao C, Wang X. Cooling control effect of water mist on thermal runaway propagation in lithium ion battery modules. Appl Energy 2020;267:115087. [CrossRef]
• [53] Behi H, Karimi D, Jaguemont J, Gandoman FH, Kalogiannis T, Berecibar M, et al. Novel thermal management methods to improve the performance of the Li-ion batteries in high discharge current applications. Energy 2021;224:120165. [CrossRef]
• [54] Shahid S, Chea B, Agelin-Chaab M. Development of a hybrid cooling concept for cylindrical li-ion cells. J Energy Storage 2022;50:104214. [CrossRef]
• [55] Wu T, Wang C, Hu Y, Fan X, Fan C. Research on spray cooling performance based on battery thermal management. Int J Energy Res 2022;46:8977–8988. [CrossRef]
• [56] Wang H, Tao T, Xu J, Shi H, Mei X, Gou P. Thermal performance of a liquid-immersed battery thermal management system for lithium-ion pouch batteries. J Energy Storage 2022;46:103835. [CrossRef]
• [57] Jang DS, Yun S, Hong SH, Cho W, Kim Y. Performance characteristics of a novel heat pipe-assisted liquid cooling system for the thermal management of lithium-ion batteries. Energy Conver Manage 2022;251:115001. [CrossRef]
• [58] Hekmat S, Molaeimanesh GR. Hybrid thermal management of a Li-ion battery module with phase change material and cooling water pipes: An experimental investigation. Appl Therm Engineer 2020;166:114759. [CrossRef]
• [59] Behi H, Karimi D, Kalogiannis T, He J, Patil MS, Muller JD, et al. Advanced hybrid thermal management system for LTO battery module under fast charging. Case Stud Therm Engineer 2022;33:101938. [CrossRef]
• [60] Bamdezh MA, Molaeimanesh GR, Zanganeh S. Role of foam anisotropy used in the phase-change composite material for the hybrid thermal management system of lithium-ion battery. J Energy Storage 2020;32:101778. [CrossRef]
• [61] Hekmat S, Bamdezh MA, Molaeimanesh GR. Hybrid thermal management for achieving extremely uniform temperature distribution in a lithium battery module with phase change material and liquid cooling channels. J Energy Storage 2022;50:104272. [CrossRef]
• [62] Singh LK, Gupta AK, Sharma AK. Hybrid thermal management system for a lithium-ion battery module: Effect of cell arrangement, discharge rate, phase change material thickness and air velocity. J Energy Storage 2022;52:104907. [CrossRef]
• [63] Wang R, Liang Z, Souri M, Esfahani MN, Jabbari M. Numerical analysis of lithium-ion battery thermal management system using phase change material assisted by liquid cooling method. Int J Heat Mass Transf 2022;183:122095. [CrossRef]
• [64] Zhou Z, Wang D, Peng Y, Li M, Wang B, Cao B, et al. Experimental study on the thermal management performance of phase change material module for the large format prismatic lithium-ion battery. Energy 2022;238:122081. [CrossRef]
• [65] Lee S, Han U, Lee H. Development of a hybrid battery thermal management system coupled with phase change material under fast charging conditions. Energy Conver Manage 2022;268:116015. [CrossRef]
• [66] Xin Q, Xiao J, Yang T, Zhang H, Long X. Thermal management of lithium-ion batteries under high ambient temperature and rapid discharging using composite PCM and liquid cooling. Appl Therm Engineer 2022;210:118230. [CrossRef]
• [67] He J, Wang Q, Wu J, Zhang Y, Chu W. Hybrid thermal management strategy with PCM and insulation materials for pulsed-power source controller in extreme oil-well thermal environment. Appl Therm Engineer 2022;214:118864. [CrossRef]
• [68] Peng P, Wang Y, Jiang F. Numerical study of PCM thermal behavior of a novel PCM-heat pipe combined system for Li-ion battery thermal management. Appl Therm Engineer 2022;209:118293. [CrossRef]
• [69] Zhang F, Zhai L, Zhang L, Yi M, Du B, Li S. A novel hybrid battery thermal management system with fins added on and between liquid cooling channels in composite phase change materials. Appl Therm Engineer 2022;207:118198. [CrossRef]
• [70] Ambekar S, Rath P, Bhattacharya A. A novel PCM and TCE based thermal management of battery module. Therm Sci Engineer Prog 2022;29:101196. [CrossRef]
• [71] Liu H, Ahmad S, Shi Y, Zhao J. A parametric study of a hybrid battery thermal management system that couples PCM/copper foam composite with helical liquid channel cooling. Energy 2021;231:120869. [CrossRef]
• [72] Chen K, Hou J, Song M, Wang S, Wu W, Zhang Y. Design of battery thermal management system based on phase change material and heat pipe. Appl Therm Engineer 2021;188:116665. [CrossRef]
• [73] Zhang W, Qiu J, Yin X, Wang D. A novel heat pipe assisted separation type battery thermal management system based on phase change material. Appl Therm Engineer 2020;165:114571. [CrossRef]
• [74] Wu X, Zhu Z, Zhang H, Xu S, Fang Y, Yan Z. Structural optimization of light-weight battery module based on hybrid liquid cooling with high latent heat PCM. Int J Heat Mass Transf 2020;163:120495. [CrossRef]
• [75] Safdari M, Ahmadi R, Sadeghzadeh S. Numerical investigation on PCM encapsulation shape used in the passive-active battery thermal management. Energy 2020;193:116840. [CrossRef]
• [76] Mashayekhi M, Houshfar E, Ashjaee M. Development of hybrid cooling method with PCM and Al2O3 nanofluid in aluminium minichannels using heat source model of Li-ion batteries. Appl Therm Engineer 2020;178:115543. [CrossRef]
• [77] Song L, Zhang H, Yang C. Thermal analysis of conjugated cooling configurations using phase change material and liquid cooling techniques for a battery module. Int J Heat Mass Transf 2019;133:827–841. [CrossRef]
• [78] Huang Q, Li X, Zhang G, Zhang J, He F, Li Y. Experimental investigation of the thermal performance of heat pipe assisted phase change material for battery thermal management system. Appl Therm Engineer 2018;141:1092–1100. [CrossRef]
• [79] Jiang G, Huang J, Liu M, Cao M. Experiment and simulation of thermal management for a tube-shell Li-ion battery pack with composite phase change material. Appl Therm Engineer 2017;120:1–9. [CrossRef]
• [80] Bai F, Chen M, Song W, Feng Z, Li Y, Ding Y. Thermal management performances of PCM/water cooling-plate using for lithium-ion battery module based on non-uniform internal heat source. Appl Therm Engineer 2017;126:17–27. [CrossRef]
• [81] Wu W, Yang X, Zhang G, Chen K, Wang S. Experimental investigation on the thermal performance of heat pipe-assisted phase change material based battery thermal management system. Energy Conver Manage 2018;138:486–492. [CrossRef]
• [82] Satheesh VK, Krishna N, Kushwah PS, Garg I, Rai S, Hebbar GS, et al. Enhancement in air-cooling of lithium-ion battery packs using tapered airflow duct. J Therm Engineer 2021;10:375–385. [CrossRef]
• [83] Ahmadi N, Rezazadeh S, Yekani M, Fakouri A, Mirzaee I. Numerical investigation of the effect of inlet gases humidity on polymer exchange membrane fuel cell (PEMFC) performance. Trans Can Soc Mech Engineer 2013;37:1–20. [CrossRef]
• [84] Ashrafi H, Pourmahmoud N, Mirzaee I, Ahmadi N. Performance improvement of proton‐exchange membrane fuel cells through different gas injection channel geometries. Int J Energy Res 2022;46:8781–8792. [CrossRef]