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What are the popular battery heat exchange solutions in the market?

Are you encountering difficulties in effectively managing heat within your battery systems? Is it challenging to identify the optimal heat exchange solution tailored for your battery needs? Explore the leading battery heat exchange solutions currently available in the market.

As new energy technologies advance, liquid cooling has become the top choice for battery heat management. Air cooling is no longer adequate for high-load and compact systems. The two leading liquid cooling options are liquid cooling plates and serpentine tubes, each designed for specific battery pack configurations.

Now, let’s dive into the different Battery Thermal Management Systems (BTMS) available, specifically focusing on liquid cooling technology.

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What Are the Different Types of Battery Thermal Management Systems?

Understanding the multitude of Battery Thermal Management Systems (BTMS) available on the market is key to making an informed decision for your specific application.

Broadly speaking, BTMS can be divided into two types: active BTMS and passive BTMS. There are also hybrid BTMS that combine elements of both types to optimize performance.

Types of Battery Thermal Management Systems - XD THERMAL

Active Thermal Management Systems

Active systems use external resources (e.g., fans, liquid coolers) to regulate battery temperature. They are more complex systems but offer precise control over the operating conditions of the battery.

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Liquid Cooling Systems

Liquid cooling is one of the most effective methods for managing battery temperatures in electric vehicles (EVs). The coolant, usually a mixture of water and glycol, flows through channels or plates in direct or indirect contact with the battery cells.

The coolant flows through a closed-loop system of pipes or plates that contact the battery cells. The battery cells conduct heat to the coolant. This method prevents the coolant from coming into direct contact with the electrical components, improving safety. The heated coolant then passes through a heat exchanger, where the heat is dissipated to the atmosphere, often with a radiator and fan assembly.

In this method, the battery cells are directly immersed in a dielectric (non-conductive) liquid. This allows for superior heat transfer because the fluid is in direct contact with the cells. You must use special coolants, and there are safety concerns. Direct liquid cooling systems can manage much higher heat loads and are useful in high-performance applications where rapid heat dissipation is critical.

Advantages
  • - High thermal conductivity ensuring efficient heat transfer.
  • - Keeps the battery pack at a uniform temperature.
  • - Effective in high-temperature environments and high-performance applications.
Disadvantages
  • - Increased system complexity and cost.
  • - Potential risk of coolant leakage, which can affect battery safety.
  • - Requires additional components like pumps and heat exchangers.
Examples

Tesla Model S and BMW i3 utilize liquid cooling systems to manage their battery temperatures effectively.

Forced Air Cooling

Forced air cooling uses fans to blow air over the battery cells, removing the excess heat through convection. It is a simpler, less expensive approach than liquid cooling but may not be as effective in extreme temperatures.

Advantages
  • - Increased system complexity and cost.
  • - Potential risk of coolant leakage, which can affect battery safety.
  • - Requires additional components like pumps and heat exchangers.
Disadvantages
  • - Less efficient heat transfer compared to liquid cooling.
  • - May lead to uneven temperature distribution, causing hotspots.
  • - Fans consume energy and can produce noise.
Examples

The Nissan Leaf and Volkswagen e-Golf have employed forced air cooling systems in their battery packs.

Thermoelectric Cooling

Thermoelectric cooling systems use the Peltier effect, where electric current creates a temperature difference across materials. This effect allows you to both heat and cool the battery pack as required.

Advantages
  • - Precise temperature control.
  • - Compact and lightweight design.
  • - No moving parts, leading to high reliability.
Disadvantages
  • - Lower efficiency compared to other cooling methods.
  • - Higher energy consumption, affecting vehicle range.
  • - More expensive due to specialized materials.

Passive Thermal Management Systems

Passive systems do not require external energy input and rely on natural heat dissipation methods.

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Passive Air Cooling

This method relies on natural convection, where heat dissipates into the surrounding air without the aid of fans or pumps.

Advantages
  • - Simplest and most cost-effective solution.
  • - No energy consumption for cooling.
  • - Minimal maintenance required.
Disadvantages
  • - Least effective in high-temperature environments.
  • - Limited control over temperature uniformity.
  • - Not suitable for high-capacity or high-performance battery packs.

Phase Change Materials (PCM)

Phase Change Materials (PCM) absorb and release thermal energy during the process of melting and solidifying at specific temperatures. By integrating PCMs with battery cells, excess heat is absorbed when the battery temperature rises, maintaining a stable temperature range.

Advantages
  • - Effective in maintaining uniform temperatures.
  • - No moving parts, reducing maintenance.
  • - Silent operation.
Disadvantages
  • - Limited thermal conductivity can slow heat transfer.
  • - Adds weight to the battery pack.
  • - Once the PCM is fully melted, it cannot absorb more heat until it solidifies.

Heat Pipes

Heat pipes are sealed tubes containing a working fluid. Heat absorbed at the evaporator end causes the fluid to vaporize and move to the condenser end, where it releases heat and condenses back into a liquid.

Advantages
  • - High thermal conductivity for efficient heat transfer.
  • - Lightweight and passive operation.
  • - Flexible design options for various battery configurations.
Disadvantages
  • - Complex manufacturing process.
  • - Potential for failure if the pipe integrity is compromised.
  • - Not as effective in high-heat scenarios without additional cooling methods.

Hybrid Thermal Management Systems

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Hybrid systems combine both active and passive methods to optimize performance and efficiency.

PCM with Liquid Cooling

Integrating phase change materials with liquid cooling systems leverages the advantages of both methods. The PCM absorbs sudden spikes in heat, while the liquid cooling system manages continuous heat removal.

Advantages
  • - Improved thermal management during peak loads.
  • - Enhanced temperature uniformity.
  • - Reduced energy consumption compared to active systems alone.
Disadvantages
  • - Increased system complexity and cost.
  • - Added weight from PCMs.

Heat Pipes with Forced Air Cooling

Combining heat pipes with forced air cooling enhances heat dissipation. The heat pipes quickly transfer heat away from the cells, and the forced air removes it from the battery pack.

Advantages
  • - Efficient heat transfer with moderate energy use.
  • - Better temperature control than passive systems alone.
Disadvantages
  • - More complex design.
  • - Potential reliability concerns with moving parts (fans).

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What Are Common Methods for Cooling High Voltage Batteries?

Having explored different types of BTMS, it is clear that the best method for cooling high voltage batteries is liquid cooling. For active systems, indirect liquid cooling (using cooling plates or tubes) is the optimal choice. If you opt for a hybrid system, PCM with liquid cooling is recommended.

XIAOMI SU7 BATTERY TECH CTB
XIAOMI SU7 BATTERY TECH CTB(from https://www.batterydesign.net/xiaomi-su7/)

For higher voltage applications, selecting a liquid-cooled BTMS offers superior thermal conductivity. At the pack level, integrating high-voltage cold plates into the battery pack helps absorb and transfer heat from the battery. The Xiaomi SU7, CTB integrated battery released in March 2024 is designed with the most robust active liquid cooling technology in the industry.

Which Is the Best Technique for Cooling EV Batteries?

the Best Technique for Cooling EV Batteries

In the electric vehicle battery thermal management systems market, liquid cooling has emerged as the preferred solution over air cooling. It handles higher heat loads and supports the compact designs required in modern EVs.

Liquid cooling plates and serpentine tubes offer precise temperature control, enhancing battery lifespan and safety compared to traditional air cooling methods.

Is It Suitable for Bottom or Side Heat Exchange?

Most people (76.2%) use bottom heat exchange for battery cooling, but if you are using cylindrical cells for your project, we suggest going with the serpentine tube.

Also, something I was seeing more of is if the heat exchange at the bottom is not enough, a multi-faceted heat exchange method with bottom and sides can also be used. We had a project before that was this multi-faceted heat exchange method, with an independent cycle on the side and a separate system on the bottom. Although the heat exchange rate has been significantly improved, the matching of pipeline accessories is more complicated. After nearly 1 weeks of iterative design updates, a suitable solution was finally found.

Bottom heat exchange typically uses liquid cooling plates to dissipate heat uniformly across the battery module. Side heat exchange may utilise serpentine tubes or heat pipes to target specific areas.  Depending on the constraints, how efficient you need to cool, and the design architecture, you might choose one over the other.

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What Customizations Are Available for Battery Liquid Cooling Plates and Tubes?

Struggling with overheating batteries that compromise performance and safety? Don’t let standard cooling solutions limit your battery’s potential. Discover how customised liquid cooling plates and tubes can precisely meet your thermal management needs.

Customisations for battery liquid cooling plates and tubes include tailored dimensions, shapes, materials, flow channel designs, connection interfaces, and surface treatments to effectively meet specific thermal management requirements.

Ready to enhance your battery system’s efficiency? Let’s delve into the customisation options available to you.

Every battery pack has unique spatial constraints and thermal requirements. Different designs—be it flat plates, curved tubes, or complex geometries—can adapt to various battery layouts. Customising the size and shape of liquid cooling plates and tubes is crucial.

The choice of material significantly impacts thermal conductivity, weight, and cost of cooling components.Custom materials like aluminum, copper, or stainless steel can be selected to meet specific needs for conductivity, durability, and budget considerations.(Aluminium offers better overall cost-performance)

Surface treatments enhance performance by improving corrosion resistance and thermal properties.

 

Custom surface treatments like anodising or insulating coatings can meet environmental and performance requirements.


Anodising improves corrosion resistance, while insulating coatings prevent electrical shorts. XD THERMAL offers various surface finishing options to ensure durability and compliance with safety standards.

Ease of integration and maintenance depends on appropriate connection interfaces and mounting methods. Customising connectors—like threaded fittings or quick-connect couplings—and mounting options ensures compatibility with your battery system.

Surface treatments enhance performance by improving corrosion resistance and thermal properties. Custom surface treatments like anodising or insulating coatings can meet environmental and performance requirements.

 

Anodising improves corrosion resistance, while insulating coatings prevent electrical shorts. XD THERMAL offers various surface finishing options to ensure durability and compliance with safety standards.

Speed is essential in product development cycles. Rapid prototyping accelerates time-to-market.


XD THERMAL offers quick design-to-sample services, enabling fast prototyping and testing to support your R&D efforts.

How to Choose the Right battery Heat Exchanger for Your Project?

Struggling to find the perfect heat exchanger for your project? You’re not alone. Common types of battery Heat Exchangers include liquid cooling tube, cold plate(with or without fins), battery tray/enclosure heat exchangers. To choose the right heat exchanger, assess your thermal needs, understand exchanger types, consider material selection, balance cost and efficiency, and consult professional suppliers.

For prismatic battery cooling, I recommend plate, and finned-tube heat exchangers, which have a large heat transfer area, and the flow path and flow resistance can be reasonably configured to achieve the optimal heat transfer efficiency.

What Is the Future Scope of Battery Thermal Management Systems?

With ongoing advancements in technology, the future of battery thermal management systems looks promising.

Future BTMS will likely focus on improved efficiency, compact designs, and integration with advanced materials and technologies to meet the evolving demands of the electric vehicle battery thermal management systems market.

Innovations may include the development of new materials with higher thermal conductivity, integration of smart thermal management systems, and advancements in high voltage cold plates. The goal is to enhance battery performance while reducing costs and environmental impact. The shift towards electrification in various industries will continue to drive this evolution.

In conclusion, choosing the right battery thermal management system is crucial for optimizing performance, safety, and longevity in modern battery systems. Liquid cooling has emerged as the preferred solution over air cooling due to its superior heat dissipation capabilities and suitability for compact designs. Understand the different types of BTMS—active, passive and hybrid—and customizing solutions like liquid cooling plates and tubes to your specific needs, you can effectively manage heat within your battery systems. Considering factors such as power demand, environmental conditions, and design constraints will guide you in selecting the most suitable cooling method for your project. Finally, stay current because there’s work on more efficient systems and smart thermal management technology that will drive even more battery performance, battery life, and sustainability.

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