Li-ion battery cooling

Cooled air

Li-ion battery
Tmax = < 40 C
Refrigerant (direct) A/C circuit
∆Twithin cell = 5 – 10K
∆Tbetw. cells = 5K

Secondary circuit

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Cell structure and cooling paths

Cathode conductor
Anode conductor
Good thermal conductivity:
 Along electrodes
Insulation
 In the conductors
 In the metallic housing

Cavities
Low thermal conductivity:
 Perpendicular to the electrodes
 In cavities Electrode stack comprising:
cathodes, anodes, separators

Housing

Potential cooling contact points

Heat flows
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Cell types

h
h d
h d
r

Cylindrical Prismatic Pouch (“coffee bag”)

Assessment with regard to cooling:

 Unfavorable surface/volume ratio  Aerodynamic when air-cooled

 Curved external surface unfavorable for  Favorable surface/volume ratio
contact with heat-conducting elements  Level external surface favorable for contact
with heat-conducting elements
 Pouch cells: efficient conductor cooling producible

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Cooling concepts for cells

a) Air cooling b) Base/head c) Cooling plates d) Fluid-ducting e) Conductor

cooling between cells cooling plates cooling

Cell
assembly ++ + 0 – +
in battery
Cooling
effectiveness 0 + + ++ +
Package
space
required – ++ + – ++
in battery

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Cooling systems for batteries
Cabin air cooling

Vehicle cabin
Evaporator
Condenser

Battery

Refrigerant
circuit
Disadvantages
Advantage
 Package space requirement of entire system
 Low complexity
 Dependence on vehicle cabin air temperature
 Low cooling performance
 Inhomogeneous temperature distribution
within battery
 Risk of fouling
 Potential safety concerns
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Cooling systems for batteries
Independent air cooling

evaporator
Vehicle cabin
Evaporator

Battery
Condenser

Battery

Refrigerant
circuit

Advantages Disadvantages
 Independent of vehicle cabin air  Package space requirement of entire system
temperature  Inhomogeneous temperature distribution
 High cooling performance within battery
 Risk of fouling

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Cooling systems for batteries
Direct refrigerant-based cooling

Compressor Evaporator plate

Evaporator
Evaporator
Condenser

plate
Battery

Refrigerant
circuit

Advantages Disadvantages
 Bauraum of entire system  Battery cooling possible only when A/C circuit
 Homogeneous temperature distribution operating
 High cooling performance  Heating cannot be integrated

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Secondary circuit with chiller and heat sink in battery

Coolant
Compressor
circuit

Evaporator
Battery cooler

Heat sink
Condenser

Battery
Chiller

Refrigerant Heating
circuit

Advantages Disadvantages
 Energy efficiency (annual average)  Package space and weight of entire system
 Compact battery module  Cost
 High cooling performance  Inertia due to high thermal mass
 Battery heating can be integrated

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Current examples
Direct refrigerant-based cooling in Mercedes S400 BlueHYBRID

First Li-ion battery to be cooled directly by refrigerant in series

production 2009

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Current examples
Direct refrigerant or coolant-based cooling and conductor cooling

Sponsored by:

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HVAC/battery system test bench
Battery, A/C circuit/secondary circuit under real operating conditions

Evaporator test section Condenser test section

Cooling Heating
 Voltage: 500 V Heating
Cooling Fan Fan
 Current: 300 A Diaphragm
Diaphragm
Flap
 Output: 65 kW Mass flow
Flap

Fan Mass flow

Heating
Cooling
Driving cycle
Dryer Heating
Compressor
Condenser
Dew point Screens
unit Auxiliary
unit HVAC
Pre-dryer

Movable wall
Fan
Fan

Climate profile
CAN

Charge/discharge

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Summary

 The approach to Li-ion battery cooling depends on the cell type and application.

 Behr has over 4 years’ experience in battery cooling and provides a tightly-knit development
process from simulation through validation.

 The world’s first direct refrigerant-based cooling system for Li-ion batteries will go into series
production in the Mercedes S400 BlueHYBRID in 2009.

 Additional series production orders for battery cooling components have been received.

 Behr has successfully developed various battery cooling systems for mild and full hybrids, plug-in
hybrids, and electric vehicles, and supplies the necessary associated components.

 Direct refrigerant-based cooling is the compact solution for mild and full hybrids.

 We favor secondary circuit cooling for plug-in hybrids and electric vehicles.
This enables valuable electric energy for powering the refrigerant compressor to be saved when
outside temperatures are low.

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