Thermal Management and Cooling System Design Strategies for Electric Vehicle Battery Packs

Abstract

Effective thermal management of electric vehicle (EV) batteries is critical for ensuring safety, performance, and longevity. Lithium-ion batteries, widely used in EVs, generate heat during charge and discharge cycles, and excessive temperatures can lead to capacity degradation, safety hazards, and reduced efficiency. This paper investigates advanced thermal management and cooling system design strategies aimed at optimizing battery temperature uniformity, heat dissipation, and energy efficiency in EV applications. A comprehensive review of passive, active, and hybrid cooling methods is presented, including air cooling, liquid cooling, phase change materials (PCMs), and heat pipe integration. The study further examines novel approaches such as refrigerant-based cooling and thermoelectric cooling systems. Utilizing computational fluid dynamics (CFD) simulations and experimental validation on a 48-cell battery pack prototype, the research evaluates the thermal performance, system complexity, weight, and energy consumption of different cooling strategies. Results demonstrate that liquid cooling systems offer superior thermal regulation and uniform temperature distribution under high-load conditions, reducing hotspot formation by up to 30% compared to air cooling. Incorporation of PCMs enhances passive thermal stability during peak loads but requires integration with active systems for effective heat removal. The study highlights trade-offs between cooling efficiency, system complexity, and vehicle energy consumption. Challenges identified include packaging constraints, coolant management, and cost implications. The paper proposes a modular hybrid cooling framework combining liquid cooling with PCM buffering for enhanced thermal control, energy efficiency, and scalability across battery sizes. Concluding, this work provides valuable insights for EV designers seeking optimized thermal management solutions to improve battery safety and performance. Future work will explore integration of AI-driven thermal control systems and eco-friendly coolant fluids to further enhance EV battery thermal management in evolving automotive contexts.