Experimental Investigation of Micro Channel Heat Pipes (MCHP) Battery Pack Cooling

Abstract

The battery thermal management system (BTMS) of lithium-ion battery packs remains a critical challenge in advancing electric vehicle (EV) technologies, particularly during fast charging. As EV adoption increases, the demand for faster charging times and higher energy capacities grows, necessitating larger battery packs. Inadequate heat dissipation can lead to severe performance degradation, reduced battery lifespan, and increased safety risks. This study explores the implementation of Micro Channel Heat Pipes (MCHPs) as an innovative cooling solution, aiming to enhance battery safety, performance, and longevity. The research focuses on evaluating the thermal performance of a six-cell prismatic battery module under three thermal management configurations: a baseline without active cooling, a traditional bottom cold plate cooling system, and the proposed MCHP cooling setup. A standardized series of experimental tests were conducted, including the Hyundai Ioniq fast charging protocol and a 10-second 400A pulse fast charging protocol at 25°C, to assess the thermal performance, temperature uniformity, and cooling effectiveness of each setup. The Bottom Cooling demonstrated the highest localized cooling effectiveness at the cell’s bottom, achieving up to 21.02% effectiveness. However, its performance diminished significantly at distant thermocouple locations, with negative effectiveness values of -3.43%, indicating localized heat accumulation. MCHP cooling, in contrast, provided more uniform cooling, achieving up to 13.58% effectiveness at the cell’s bottom and notably outperforming Bottom cooling at distant points with 13.42% effectiveness, demonstrating its ability to distribute heat more evenly throughout the cells. The results demonstrate that MCHP cooling excels in providing consistent and distributed cooling, effectively mitigating thermal hotspots, and adequate cooling performance compared to Bottom cooling. The MCHP system presents a promising BTMS solution for next-generation EVs. Further optimization of the MCHP design and integration is required for improved cooling efficiency, supporting the growing demands for faster charging, enhanced safety, and prolonged battery life in electric vehicles.