Materials Today: Proceedings xxx (xxxx) xxx
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Materials Today: Proceedings
journal homepage: www.elsevier.com/locate/matpr
Battery thermal management system for the cooling of Li-Ion batteries,
used in electric vehicles
Saurav Sikarwar a, Rajesh Kumar a,⇑, Ashok Yadav a, Manoj Gwalwanshi b
a
b
Dayalbagh Educational Institute, India
Graphic Era University, India
a r t i c l e
i n f o
Article history:
Available online xxxx
Keywords:
Lithium-Ion battery
Battery thermal management system
Cooling methods
a b s t r a c t
Conventional technology has avital role in increased greenhouse gas emission, which is harmful for the
environment. A major part of rising emission is emitted by traditional vehicle technologies. The use of
carbon-based fuels plays a major roll in rising pollution levels. The amount of pollution can be reduced
nearly sixty percent. Globally by avoiding fossil fuel. Vehicles are gaining popularity. Now day Electric
vehicles (EVs) have nearly negligible tail emissions, which contributes significantly to reduce pollution
levels. Lithium-ion (Li-Ion) batteries in EVs, performance well within a small temperature range. There
for management of temperature of Li-Ion battery pack is important for battery pack & cell life BTMS is
used for effective temperature management. The Battery Thermal Management System (BTMS) is the
component in charge of controlling and dissipating the heat produced by the electrochemical reactions
taking place in the cells, enabling the battery to function safely and effectively. Air-based, liquid-based,
and phase change material (PCM)-based are the three most frequent mediums utilized in BTMSs.
Future work will focus on liquid-cooled BTMSs, PCM based & hybrid type BTMSs. The lithium-ion battery
pack gives better performance in the temperature limits of 15 °C to 35 °C. This review paper talks about
how thermal management systems (BTMSs) can be used with different methods and materials to keep
the temperature within the desirable range (15 °C to 35 °C).
Ó 2023 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the Recent Advances in
Materials, Manufacturing and Thermal Engineering.
1. Introduction
Greenhouse gas emission thrown out by conventional internal
combustion engine-based vehicles is one of the primary cause of
environment pollution. Many researchers are trying to figure out
the causes of rise in greenhouse gases emissions. The fossil fuels
used by power plants, industry and factories, household activities,
and the automobile emits a lot of pollution, Therefore the conventional technology used in the automobile sector is the biggest reason for greenhouse emissions [1]. In this regard, it is a must to find
another green alternative for transportation purposes [2,3]. Conventional technology uses a great deal of fossil fuel, which
increases the greenhouse effects and also causes a drastic change
in the climate [4]. At that time, a higher percentage of greenhouse
⇑ Corresponding author at: Mechanical Department, Faculty of Engineering,
Dayalbagh Educational Institute, Agra, U.P.
E-mail addresses: sauravsikarwar019@gmail.com (S. Sikarwar), kumarrajesh.
iitr@gmail.com (R. Kumar).
emissions were due to fossil fuels, which increased greenhouse
emissions at a very alarming rate. Furthermore, all over the world,
governments are switching to another alternative to conventional
technology, which is electricity [1]. That is why the electric vehicle
is more popular everywhere and decreases greenhouse pollution
effects as well as the demand for fossil fuel. In this paper, the
author focused only on replacing conventional technology with
electric-driven vehicles. In this way, almost every country suggested the electric vehicle, but each one had different benefits
and rules for both consumers and carmakers. As a result, pollution
levels in the EV industries are decreasing and rapidly increasing
[5,6]. Although there are a lot of advantages to using an electric
vehicle, there are still a few problems with it, such as range anxiety
because there are very few charging substations while a gasoline
pump is more than enough, and another one is the battery. According to a literature review, almost all electric vehicles use lithiumion batteries because they are better for electric vehicles. [7]
According to the literature review, it is therefore necessary to
understand why lithium-ion batteries lose capacity and perfor-
https://doi.org/10.1016/j.matpr.2023.02.293
2214-7853/Ó 2023 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the Recent Advances in Materials, Manufacturing and Thermal Engineering.
Please cite this article as: S. Sikarwar, R. Kumar, A. Yadav et al., Battery thermal management system for the cooling of Li-Ion batteries, used in electric
vehicles, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2023.02.293
S. Sikarwar, R. Kumar, A. Yadav et al.
Materials Today: Proceedings xxx (xxxx) xxx
above mentioned two cooling methods is how they are using aircooled BTMS, these are now classified by the type of coolant used,
whereas air-based BTMS uses air as the coolant. The battery module of EVs uses direct air from the environment; that air moved
over the battery pack after cooling; this air then released into the
environment [20]. Maintenance of air based BTMS is easy also,
there are two types of air-cooled BTMS.
mance. In the case of a lithium-ion battery, the operating temperature and uniformity of temperature in the whole battery pack are
most important; otherwise, the battery pack degrades and shortens the life of the battery [8,9].
Therefore, to achieve the controlled temperature and uniformity of temperature in the whole battery pack, thermal management is must otherwise, it would not perform well [10].
Variation in temperature directly affects the lithium-ion battery’s
performance and its life time, if it is not managed within the limit.
Hence the lithium-ion battery is very sensitive to temperature. The
EV manufacturers are also more concern about the battery thermal
management. The battery’s thermal management system controls
the temperature within a limited range [11,12]. During the high
rate of discharge and charge (C-rate), the lithium-ion battery generates more heat. According to the literature review, the optimum
temperature is range is defined from 15 °C to 35 °C as shown in
Fig. 1. If the temperature is lower than 15 °C, the electrolyte reaction slow, which can lowers the capacity and performance of the
battery during charging and discharging. Similarly, when the temperature inside the battery exceeds 35 °C during charging and discharging, the capacity and performance of the battery start
reducing which leads to increased possibilities of thermal runaway
[1].
To achieve this narrow limit of temperature, numerous techniques have been investigated, for battery thermal management
system (BTMS). The techniques used are air, phase change material
(PCM), or liquid heat pipe based [10].
2.1.1. Natural convection air based BTMS
In natural convection, the dissipation of heat depends on the
external airflow, the externally facing forward drive of the EV to
the lithium-ion battery pack. As a result, heat generated by the battery pack is released into the environment via an external flow of
air. Various studies define that good performance of cooling the
battery pack depends on two factors: the first layout of batteries,
and second is geometry of airflow through the battery pack [21].
As shown in Fig. 2, when the EV moves forward the air flows naturally in backward direction. The natural cooling of the battery
pack is caused by the airflow over it naturally without any external
force. The natural convection does not require electronic and electrical devices to force air to flow [22].
2.1.2. Forced convection air based BTMS
In forced convection, an additional fan is used for forced airflow
to cool the battery pack because natural convection is not enough
for the heavy battery pack of EVs. Forced airflow over the battery
pack gives more efficient cooling in comparison to natural convection cooling [12]. Fig. 3 shows that pre-cooled air is supplies from
the air conditioning system [23]. Wang et al. suggested that the
ambient temperature of air below 20 °C is not necessary for forced
convection cooling [25].
2. Types of BTMS
It is required to maintain the optimal temperature of the
lithium-ion battery pack in the EVs, which can be achieved using
battery thermal management system (BTMS). It serves the following purposes: removing the heat from the battery pack if the temperature is low, maintaining the temperature with the help of
BTMS, also ventilation for gases [14]. BTMSs must be as small as
possible, light, need less building, be more reliable, need less and
easy maintenance, Several BTMS have been suggested in the literature for keeping the battery configuration and temperature within
a narrow range [17]. Manly three types of BTMSs can be used.
2.2. Phase change material based BTMS
The phase change material (PCM) is used in the phase change
material-based BTMS for the storage of latent heat. It is one of
the simplest methods of storing thermal energy and also has a high
energy density for isothermal storage. PCMs have been widely used
in the thermal management of systems for heat pumps, solar engineering, and electric vehicles. For higher temperature limits of Liion battery pack the PCM melts and solidifies as shown in figure
number 4 [26]. When a material changes phases from solid to liquid or liquid to solid, it transfers fundamental thermal energy from
one form to another, resulting in PCM behaviors similar to traditional storage materials. When the temperature rises, PCM absorbs
heat, and vice versa when the temperature is nearly constant. It
was found in previous studies that PCM can store about 5–14 times
more heat per unit volume [27].
The idle PCM has a melting point between 30 °C and 60 °C,
which is beneficial for the narrow temperature limit of the
lithium-ion battery pack. The lithium-ion battery pack has a lot
of modules, and those modules have many cells that are connected
in series or parallel according to the energy demand of EVs. For
example, a few lines of lithium-ion cells are connected in series,
while a few are connected in parallel to each other, like 26S8P,
which fulfils the capability and voltage requirement of the battery
pack for EVs Application. Fig. 5 shows the lithium-ion battery pack
with PCM [29].
2.1. Air based BTMS
The air-based BTMSs used in EVs, is most conventional method.
The air is easily and freely available that is why the air-based
BTMSs is adopted because due to simple construction and economic [18]. Air-based BTMS is a simple way to remove heat from
inside the battery pack, and it is also advantageous due to the
smaller space requirement for EVs [19]. Air-based BTMS, two categories: the first is the passive air cooling system, which is based on
natural convection process, whereas the second is the active air
cooling system, which uses forced convection with the help of a
fan and different channels [17]. The main difference between the
Fig. 1. Temperature influence the performance Of Lithium-Ion battery [13].
Fig. 2. Natural convection air based [24].
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S. Sikarwar, R. Kumar, A. Yadav et al.
Fig. 3. Forced convection air based [13].
Fig. 6. Direct liquid cooling based BTMS [32].
Fig. 4. Phase change during heating the substance (temperature vs. time) [28].
Fig. 7. Indirect liquid cooling based BTMS [32].
2.3. Liquid based BTMS
pack in liquid or oil has large surface area for heat dissipation
[31]. As the air cooling BTMS has two ways to cooling natural
and forced. Similarly, there are two ways of cooling with liquid
based: direct cooling and indirect cooling based BTMS. [32].
In liquid-based BTMSs any liquid coolants and oils are used as
cooling medium. This type of BTMS is more efficient as compared
to other systems. It maintains the temperature of the battery pack
with in the safe limit more effectively and quickly. Lithium-ion
battery pack doesn’t come into direct contact with the coolant
because it has blocks, pipes, and channels [30]. Many researchers
concluded that a good air flow rate can remove heat from the battery pack in electric vehicles with air-cooled BTMS when fast generates more heat [33,35]. But air has a very low thermal
conductivity than that for liquid fluids. It is very difficult to prevent
the thermal runaway in the battery pack using air based BTMS. In
that case, use of liquid coolants can be another alternative of air
based BTMS. The liquid coolants are supplied through liquid jackets, tubes, and different pattern cold plates to construct a liquid
based BTMS. Also various geometrical arrangements for batteries
are being tested by researchers. The directly submerged battery
2.3.1. Direct liquid cooling based BTMS
Fig. 6 shows that the whole battery pack is submerged in the
liquid fluid or oil tank. A circulating pump moves the coolant
through the heat exchanger to return the battery pack to its original state [32].
2.3.2. Indirect liquid cooling based BTMS.
In indirect liquid cooling-based BTMS, the coolant does not
come in direct contact with the battery pack. As shown in Fig. 7,
a tube, channels, and cold plates are used between the coolant fluid
and the battery pack. This can be concluded that PCM and liquid
based BTMSs are more effective for higher temperature range.
Fig. 5. Lithium-Ion battery pack with PCM [29].
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Materials Today: Proceedings xxx (xxxx) xxx
Fig. 8. Materials used as coolant in BTMS.
Table 1
Summary of BTMS.
S.
No.
Ref.
Variables
Battery
Type
Coolant
Type
Cooling
Type
No. of
batteries
in pack
Charging
and/or
Discharging
Rate
Method
Findings
1
Hussam
et al.
[10]
Power and energy
density
Prismatic,
lithium-ion
battery
Air &
liquid
based
Passive
and
active
3
1C–3C
Chemical reactions increased at hotter
batteries. The heat raised caused loss the
battery capacity and increased self-discharge
rate
2
Maosung wu
et al.
[33]
Current, heat and
state-of-discharge
Cylindrical,
lithium-ion
battery
Liquid
based
Active
1
2C
3C
Temperature
management
with air,
liquid and
PCM
Liquid cooling
3
Suman
basu
et al.
[34]
Paul
Nelson
et al.
[35]
Coolant flow-rate
and current
Cylindrical,
lithium-ion
battery
Liquid
based
Active
30
0.6 C
0.9 C
Area-specific
impedances, the
lumpedparameter, layer
thicknesses
Heat generation,
different C rate
and time
Flat-wound
cells,
lithium-ion
battery
Air &
liquid
based
Active
48
1C
Air and liquid
pouch cells,
Lithium-ion
battery
Liquid
based
Active
1
1C – 5C
Liquid cooling
4
5
L.H. Saw
et al.
[36]
Liquid cooling
(by
simulation)
Temperature decreased, when the heat pipe
is used with fins, the difference between of
maximum and minimum temperature is
20 °C, at the end of discharged, temperature
is 65 °C while current does not exceed 10 A
Conduction element is worked as a separator,
taking the heat through thermal conduction;
maximum temperature is within 7 K at high
discharged & low coolant flow rate.
High power required, air as the heat transfer
medium, During the first few year at 10 °C,
more battery life, Refrigeration system is
more reliable, for not suffer the power loss
Liquid cooling is more efficient to removes
the heat from the battery pack, Performance
of EVs directly affected to temperature
2. To maintain the cell temperature with in the safe limit various
cooling techniques have been tested and compared. Battery
thermal management system (BTMS) is one of such good technique. The air-based, PCM-based and liquid-based are three
commonly types of BTMSs.
3. Air-based BTMSs are adopted due to their simple construction
and economic operation as air is freely available. There are
two types of air-cooled BTMS: natural convection air-based
BMTS and forced convection air-based BMTS.
4. PCMs have been widely used in the thermal management of
systems for heat pumps, solar engineering, and electric vehicles.
The PCM melts and solidifies and stores heat during its phase
change. PCM can store 5–14 times more heat per unit volume.
Therefore PCM is also a good option for heat dissipation from
battery packs.
5. Liquid-cooled BTMSs are capable of removing the heat from the
battery pack using any liquid as coolant. Liquid based BTMS has
many benefits such as high heat transfer capabilities. These are
more compact for the same heat removal, and the liquid fluid
has a better density.
6. Future this study suggests that liquid cooling type BTMSs and
hybrid BTMSs (a combination of two types of BTMS) can give
best results.
Some of the recent studies are also available with the combination
of PCM and any of the other cooling technique to form a hybrid
system. This can be helpful in combining the advantages of both
the systems (see Fig. 8).
The comparative summary of some of the studies with various
types of BTMSs and their findings in tabular form is given below
(see Table 1):
3. Conclusion
The above studies find BTMS an effective and essential component to improve the performance and life cycle of battery pack.
Mainly three types of BTMSs viz. air based, liquid based and PCM
based are used. This study concludes the comparative analysis of
all three systems with different materials and combinations of
parameters. The following conclusion are made:
1. The lithium-ion battery is most suitable for EVs due to its high
energy density, longer cell life and less self-discharging.
Although the thermal runaway due to high temperature
attained at charging discharging capacity, is one of the major
problem.
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Data availability
Data will be made available on request.
Declaration of Competing Interest
The authors declare that they have no known competing financial interests or personal relationships that could have appeared
to influence the work reported in this paper.
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