Assessment of a Top and Bottom Cooling Strategy for Prismatic Lithium-Ion Cells Intended for Automotive Use

In contemporary vehicle applications, lithium-ion batteries have become a leading option among the diverse array of battery technologies available. This preference is attributed to their advantageous properties, which include low self-discharge rates and no memory effect. Despite these benefits, lithium-ion batteries are not without their challenges. The key issues include a restricted driving range, concerns regarding longevity, safety risks, and prolonged charging durations. Efforts aimed at minimizing the charging duration frequently entail the introduction of elevated currents into the battery, a practice that can significantly elevate its temperature and, in turn, diminish its operational lifespan. Generally, battery packs in electric vehicles are equipped with flat cooling plates located on their side or bottom surfaces, which also serve the dual purpose of providing heating in colder conditions. Nevertheless, this cooling configuration faces difficulties during fast charging and may not efficiently heat or cool the batteries. In this work, a novel thermal management approach is proposed, in which a battery module is cooled not only with a bottom cooling plate but also using another cooling plate in contact with the busbars, located on the top of the battery module. The simulations and experimental tests show that this new configuration demonstrates significant improvements. The thermal time constant is reduced by 47%, enabling faster cooling of the module. Additionally, the maximum temperature reached by the battery during charging with dual cooling is lowered by 6 °C compared to the conventional approach. In this configuration, the top cooling plate acts as a thermal bridge. This is a key advantage that promotes temperature homogenization within the battery module. As a result, it supports an even aging process of batteries, ensuring their longevity and optimal performance.