Reciprocating air flow for Li-ion battery thermal management to improve temperature uniformity

The thermal management of traction battery systems for electrical-drive vehicles directly affects vehicle dynamic performance, long-term durability and cost of the battery systems. In this paper, a new battery thermal management method using a reciprocating air flow for cylindrical Li-ion (LiMn₂O₄/C) cells was numerically analyzed using (i) a two-dimensional computational fluid dynamics (CFD) model and (ii) a lumped-capacitance thermal model for battery cells and a flow network model. The battery heat generation was approximated by uniform volumetric joule and reversible (entropic) losses. The results of the CFD model were validated with the experimental results of in-line tube-bank systems which approximates the battery cell arrangement considered for this study. The numerical results showed that the reciprocating flow can reduce the cell temperature difference of the battery system by about 4 °C (72% reduction) and the maximum cell temperature by 1.5 °C for a reciprocation period of τ = 120 s as compared with the uni-directional flow case (τ = ∞). Such temperature improvement attributes to the heat redistribution and disturbance of the boundary layers on the formed on the cells due to the periodic flow reversal.     

Application of infrared thermal imaging to the study of pellet solid oxide fuel cells

The application of infrared thermal imaging to the study of solid oxide fuel cells is demonstrated. The temperature increase accompanying polarisation of gadolinium doped ceria pellet cells is measured and the effect of temperature increase on polarisation characteristics is modelled. Temperature increases of the order of 2.5 °C were measured for heavily loaded pellet cells. Measurement accuracy of 0.1 °C and spatial resolution of 0.5 mm allow temperature distribution heterogeneity to be clearly discerned. A total heat transfer coefficient is derived from experimental results that allow the development of a model that predicts the extent of self-heating. For pellet fuel cells, self-heating is not expected to have a large effect on the polarisation characteristics; however, for thin electrolytes and high current density the effect becomes appreciable.     

Thermal modeling of a cylindrical LiFePO4/graphite lithium-ion battery

A lumped-parameter thermal model of a cylindrical LiFePO₄/graphite lithium-ion battery is developed. Heat transfer coefficients and heat capacity are determined from simultaneous measurements of the surface temperature and the internal temperature of the battery while applying 2 Hz current pulses of different magnitudes. For internal temperature measurements, a thermocouple is introduced into the battery under inert atmosphere. Heat transfer coefficients (thermal resistances in the model) inside and outside the battery are obtained from thermal steady state temperature measurements, whereas the heat capacity (thermal capacitance in the model) is determined from the transient part. The accuracy of the estimation of internal temperature from surface temperature measurements using the model is validated on current-pulse experiments and a complete charge/discharge of the battery and is within 1.5 °C. Furthermore, the model allows for simulating the internal temperature directly from the measured current and voltage of the battery. The model is simple enough to be implemented in battery management systems for electric vehicles.     

Preparation and properties of palmitic acid/SiO2 composites with flame retardant as thermal energy storage materials

Palmitic acid/silicon dioxide (SiO₂) composites with flame retardant as thermal energy storage materials were prepared using sol-gel methods. In the composites, palmitic acid was used as the phase change material (PCM) for thermal energy storage, and SiO₂ acted as the supporting material. In order to improve flame retardant property of the composites, melamine was added in the composites. Fourier transformation infrared spectroscope (FT-IR), X-ray diffractometer (XRD) and scanning electronic microscope (SEM) were used to determine chemical structure, crystalloid phase and microstructure of palmitic acid/SiO₂ composites, respectively. The thermal properties, such as phase change temperature and latent heat, were investigated by a differential scanning calorimeter (DSC). Thermal stability was determined by a thermogravimetric analyzer (TGA). The SEM results showed that palmitic acid was well dispersed in the porous network of SiO₂. The DSC results indicated that the composites solidify at 59.20 °C with a latent heat of 60.55 kJ/kg and melt at 59.76 °C with a latent heat of 85.11 kJ/kg when the mass percentage of palmitic acid in the composites was 41.1%. The TGA results showed that addition of melamine improved thermal stability. The microstructure of the charred residue after combustion indicated that the homogeneous and compact charred residue decreased the flammability of the composites.     

Effects of temperature dependent thermal conductivity on Nu number behavior in micro-tubes

The numerical modeling of the conjugate heat transfer and fluid flow through the micro-tube was presented in the paper. Three different fluids with temperature dependent fluid properties are considered: water and two dielectric fluids, HFE-7600 and FC-70. The diameter ratio of the micro-tube was D_i/D_o = 0.1/03 mm with a tube length L = 70 mm, geometry used in [D. Lelea, Nishio S., Takano K., The experimental research on microtube heat transfer and fluid flow of distilled water, International Journal of Heat and Mass Transfer 47 (2004) 2817–2830]. The laminar fluid flow regime is analyzed. Two different heat transfer conditions are considered: heating and cooling. The influence of the temperature dependent thermal conductivity on Nu number is analyzed for these two cases and compared with k = const.     

Development and characterization of a bilayer separator for lithium ion batteries

A battery separator is placed between the positive and negative electrodes to prevent electric contact of the electrodes while maintaining good ionic flow. The most commonly used separators for lithium-ion batteries are porous polyolefin membranes. However, they generally do not have good dimentional stability at elevated temperatures. In this study, a bilayer separator has been formed directly on an anode. This bilayer separator comprised a ceramic layer and a porous polyvinylidene fluoride (PVDF) layer. Coin cells with this type of separators showed stable cycling performance at room temperature. They also showed significantly improved rate capabilities compared to the reference cell with a conventional polyolefin separator. An oven test has been used to characterize the cells thermal stability. Charged cells were kept in an oven at 150 °C and their voltage drop was recorded. The reference cell with a conventioal separator failed within about 50 min, while no noticeable voltage drop was observed for the cells with the new bilayer separator within the measured 2 h.     

A simple method for the estimation of thermal insulation thickness

Selection and determination of optimum thickness of insulation is of prime interest for many engineering applications. In this study, a simple method is developed to estimate the thickness of thermal insulation required to arrive at a desired heat flow or surface temperature for flat surfaces, ducts and pipes. The proposed simple method covers the temperature difference between ambient and outside temperatures up to 250 °C and the temperature drop through insulation up to 1000 °C. The proposed correlation calculates the thermal thickness up to 250 mm for flat surfaces and estimates the thermal thickness for ducts and pipes with outside diameters up to 2400 mm. The accuracy of the proposed method was found to be in excellent agreement with the reported data for wide range of conditions where the average absolute deviation between reported data and the proposed method is around 3.25%. The method is based on basic fundamentals of heat transfer and reliable data. Therefore the formulated simple-to-use expression is justified and applicable to any industrial application.     

A three-dimensional thermal abuse model for lithium-ion cells

To understand further the thermal abuse behavior of large format Li-ion batteries for automotive applications, the one-dimensional modeling approach formulated by Hatchard et al. [T.D. Hatchard, D.D. MacNeil, A. Basu, J.R. Dahn, J. Electrochem. Soc. 148(7) (2001) A755–A761] was reproduced. Then it was extended to three dimensions so we could consider the geometrical features, which are critical in large cells for automotive applications. The three-dimensional model captures the shapes and dimensions of cell components and the spatial distributions of materials and temperatures, and is used to simulate oven tests, and to determine how a local hot spot can propagate through the cell. In simulations of oven abuse testing of cells with cobalt oxide cathode and graphite anode with standard LiPF₆ electrolyte, the three-dimensional model predicts that thermal runaway will occur sooner or later than the lumped model, depending on the size of the cell. The model results showed that smaller cells reject heat faster than larger cells; this may prevent them from going into thermal runaway under identical abuse conditions. In simulations of local hot spots inside a large cylindrical cell, the three-dimensional model predicts that the reactions initially propagate in the azimuthal and longitudinal directions to form a hollow cylinder-shaped reaction zone.     

A parabolic dish/AMTEC solar thermal power system and its performance evaluation

This paper proposes a parabolic dish/AMTEC solar thermal power system and evaluates its overall thermal–electric conversion performance. The system is a combined system in which a parabolic dish solar collector is cascaded with an alkali metal thermal to electric converter (AMTEC) through a coupling heat exchanger. A separate type heat-pipe receiver is selected to isothermally transfer the solar energy from the collector to the AMTEC. To assess the system’s overall thermal–electric conversion performance, a theoretical analysis has been undertaken in conjunction with a parametric investigation by varying relevant parameters, i.e., the average operating temperature and performance parameters associate with the dish collector and the AMTEC. Results show that the overall conversion efficiency of parabolic dish/AMTEC system could reach up to 20.6% with a power output of 18.54 kW corresponding to an operating temperature of 1280 K. Moreover, it is found that the optimal condenser temperature, corresponding to the maximum overall efficiency, is around 600 K. This study indicates that the parabolic dish/AMTEC solar power system exhibits a great potential and competitiveness over other solar dish/engine systems, and the proposed system is a viable solar thermal power system.     

High latent heat storage and high thermal conductive phase change materials using exfoliated graphite nanoplatelets

Using exfoliated graphite nanoplatelets (xGnP), paraffin/xGnP composite phase change materials (PCMs) were prepared by the stirring of xGnP in liquid paraffin for high electric conductivity, thermal conductivity and latent heat storage. xGnP of 1, 2, 3, 5 and 7 wt% was added to pure paraffin at 75 °C. Scanning electron microscopy (SEM) morphology showed uniform dispersion of xGnP in the paraffin wax. Good dispersion of xGnP in paraffin/xGnP composite PCMs led to high electric conductivity. The percolation threshold of paraffin/xGnP composite PCMs was between 1 and 2 wt% in resistivity measurement. The thermal conductivity of paraffin/xGnP composite PCMs was increased as xGnP loading contents. Also, reproducibility of paraffin/xGnP composite PCMs as continuous PCMs was manifested in results of electric and thermal conductivity. Paraffin/xGnP composite PCMs showed two peaks in the heating curve by differential scanning calorimeter (DSC) measurement. The first phase change peak at around 35 °C is lower and corresponds to the solid-solid phase transition of the paraffin, and the second peak is high at around 55 °C, corresponding to the solid-liquid phase change. The latent heat of paraffin/xGnP composite PCMs did not decrease as loading xGnP contents to paraffin. xGnP can be considered as an effective heat-diffusion promoter to improve thermal conductivity of PCMs without reducing its latent heat storage capacity in paraffin wax.     

Experimental study of forced and free convective heat transfer in the thermal entry region of horizontal concentric annuli

Forced and free convective heat transfer for thermally developing and thermally fully developed laminar air flow inside horizontal concentric annuli in the thermal entrance length has been experimentally investigated. The experimental setup consists of a stainless steel annulus having a radius ratio of 2 and an inner tube with a heated length of 900 mm subjected to a constant wall heat flux boundary condition and an adiabatic outer annulus. The investigation covers Reynolds number range from 200 to 1000, the Grashof number was ranged from 6.2 × 10⁵ to 1.2 × 10⁷. The entrance sections used were long tube with length of 2520 mm (L/D_h = 63) and short tube with length of 504 mm (L/D_h = 12.6). The surface temperature distribution along the inner tube surface, and the local Nusselt number distribution versus dimensionless axial distance Z_t were presented and discussed. It is inferred that the free convection effects tended to decrease the heat transfer at low Re number while to increase the heat transfer for high Re number. This investigation reveals that the Nusselt number values were considerably greater than the corresponding values for fully developed combined convection over a significant portion of the annulus. The average heat transfer results were correlated in terms of the relevant dimensionless variables with an empirical correlation. The local Nusselt number results were compared with available literature and show similar trend and satisfactory agreement.     

Galactitol hexa stearate and galactitol hexa palmitate as novel solid-liquid phase change materials for thermal energy storage

Galactitol has a melting point of 187.41 °C and a fusion enthalpy of 401.76 J g⁻¹. Its melting temperature is not suitable for many thermal energy storage applications although it has good latent heat storage capacity compared to the several traditional phase change materials (PCMs). The galactitol also has high supercooling degree as about 72 °C. These unfavorable properties limit the usage potential of galactitol in thermal energy storage applications. However, the phase change temperature and supercooling degree of galactitol can be reduced to a reasonable value and therefore its feasibility for energy storage systems can be increased. For this aim, in this study, galactitol hexa stearate (GHS) and galactitol hexa palmitate (GHP) were prepared as novel solid-liquid PCM by means of esterification reaction of the galactitol with palmitic acid and stearic acid. The GHP and GHS esters were characterized chemically using FT-IR and ¹H NMR techniques. By using DSC analysis method, the melting temperature and latent heat value of the PCMs were determined as 31.78 °C and 201.66 J g⁻¹ for GHP ester and 47.79 °C and 251.05 J g⁻¹ for GHS ester. Thermal cycling test showed that the prepared PCMs had good thermal reliability after thermal 1000 melting-freezing cycles. Thermogravimetric analysis (TGA) results revealed that the PCMs have good thermal stability over their working temperatures. In addition, thermal conductivity of the prepared PCMs was increased as about 26.3% for GHP and 53.3% for GHS by addition of 5 wt.% expanded graphite. Based on all results it can be concluded that the prepared GHP and GHS esters can be considered as promising solid-liquid PCMs for many energy storage applications such as solar energy storage, indoor temperature controlling in buildings, production of smart textile and insulation clothing due to their good energy storage properties.     

Thermal property characterization of a low melting-temperature ternary nitrate salt mixture for thermal energy storage systems

Molten salts have better thermal properties than synthetic mineral oil, and hence they can be directly used as heat transfer fluids in solar power plants, but in practice their direct applications as heat transfer fluids are constrained due to their high freezing temperature points. In this paper, a class of ternary nitrate salt mixtures consisting of 50-80 wt% KNO₃, 0-25 wt% LiNO₃ and 10-45 wt% Ca(NO₃)₂ were processed and tested. Experimental results indicated that some mixtures within this range exhibited excellent thermal properties, such as a low melting point (<100 °C), robust reliability, high-temperature stability (upto 500 °C) and a low viscosity (e.g.,<5 cP at 190 °C). Apart from these desirable thermo-physical properties, the manufacturing cost of these novel inorganic salts HTFs (Heat Transfer Fluids) is considerably lower than those of the existing commercial heat transfer fluids (HTFs).     

Determination of the thermal transport properties of ammonia borane and its thermolysis product (polyiminoborane) using the transient plane source technique

Reliable thermal property data are necessary to improve the fidelity of chemical hydride thermal decomposition models. The thermal diffusivity and conductivity of ammonia borane (NH₃BH₃) and its partial thermolysis product (polyiminoborane) were measured at various packing densities using a transient plane source technique under ambient conditions. The particle size of the ammonia borane powder was between 200 and 600 μm, while the particle size of the polyiminoborane powder was between 10 and 30 μm. The thermal diffusivity and conductivity of the ammonia borane increased from 0.17 to 0.24 mm²/s and 0.19 to 0.44 W/m K (±10%), respectively, when its packing density was increased from 0.37 to 0.58 g/cm³. The increase in thermal conductivity is due to the increase in contact area between particles and the increase in the thermal diffusivity is related to an increase in density and volumetric heat capacity caused by compaction. The thermal conductivity of the polyiminoborane powder was approximately three times lower, likely due to its higher porosity. The thermal diffusivity and conductivity of this product changed from 0.21 to 0.12 mm²/s and 0.068 to 0.23 W/m K (±10%), respectively, when its packing density was increased from 0.13 to 0.96 g/cm³.     

Thermoelectric water-cooling device applied to electronic equipment

This article investigates the thermal performance of a thermoelectric water-cooling device for electronic equipment. The influences of heat load and the thermoelectric cooler's current on the cooling performance of the thermoelectric device are experimentally and theoretically determined. This study develops a novel analytical model of thermal analogy network to predict the thermal capability of the thermoelectric device. The model's prediction agrees well with the experimental data. The experimental result shows that when heat load increases from 20 W to 100 W, the lowest overall thermal indicator increases from − 0.75 KW^− 1 to 0.62 KW^− 1 at the optimal electric current of 7 A. Besides, this study verifies that the thermal performance of the conventional water-cooling device can be effectively enhanced by integrating it with the thermoelectric cooler when the heat load is below 57 W.     

Combustion and heat transfer at meso-scale with thermal recuperation

Results are presented from successfully designed and fabricated meso-scale ceramic combustors that incorporate internal thermal energy recirculation. The combustor provided sustained operation using propane and air as the reactants. Flames could be obtained well below the normal quenching distance. The development required examination of several different combustor designs and materials. Flammability limits of these combustors have been determined experimentally. Experimental investigations have been performed on the effects of flame holder geometry, material conductivity, equivalence ratio, and inlet Reynolds number on the combustor performance. Measurement of the reactant preheating and product exhaust temperatures was performed using K-type thermocouples which were installed with minimal intrusion to the flow. The reactant preheating temperatures were observed to be in the range 700 K–1000 K. However, the combustor suffered significant overall heat loss (50–85%) which was implied by the low exhaust temperatures (500 K–750 K). For a constant fuel flow rate, the exhaust temperature increased monotonously with decrease in equivalence ratio until the blow-off condition implying that the combustor’s maximum thermal efficiency occurs at its lean blow-off limit. Thermal imaging of the combustor walls was performed using infrared camera to obtain the temperature distribution within the combustor. Numerical simulations were performed with the aid of CFD software using a heat loss coefficient chosen so as to give best correlation with experimental results. These CFD simulations helped to obtain better insight of the dependence of combustor performance on thermal conductivity of the material and heat load.     

Lithium battery thermal models

Thermal characteristics and thermal behavior of lithium batteries are important both for the batteries meeting operating life requirements and for safety considerations. Sandia National Laboratories has a broad-based program that includes analysis, engineering and model development. We have determined thermal properties of lithium batteries using a variety of calorimetric methods for many years. We developed the capability to model temperature gradients and cooling rates of high-temperature primary lithium thermal batteries several years ago. Work is now under way to characterize the response of ambient-temperature rechargeable lithium-ion batteries to thermal abuse. Once the self-heating rates of lithium cells have been established over a range of temperatures, the thermal response can be estimated under a variety of conditions. We have extended this process to isolate the behavior of individual battery components and have begun to understand the chemical nature of the species responsible for heat evolution within the cells. This enhanced level of understanding will enable more accurate modeling of cell thermal behavior and will allow model-based design of safer, more abuse-tolerant lithium batteries for electric vehicles (EVs) and hybrid electric vehicles (HEVs) in the future. Progress toward this goal and key information still needed to reach it are discussed.     

Theoretical and experimental analysis of the vacuum pressure in a vacuum glazing after extreme thermal cycling

Details of theoretical and experimental studies of the change in vacuum pressure within a vacuum glazing after extreme thermal cycling are presented. The vacuum glazing was fabricated at low temperature using an indium-copper-indium edge seal. It comprised two 4 mm thick 0.4 m by 0.4 m glass panes with low-emittance coatings separated by an array of stainless steel support pillars spaced at 25 mm with a diameter of 0.4 mm and a height of 0.15 mm. Thermal cycling tests were undertaken in which the air temperature on one side of the sample was taken from −30 °C to +50 °C and back to −30 °C 15 times while maintaining an air temperature of 22 °C on the other side. After this test procedure, it was found that the glass to glass heat conductance at the centre glazing area had increased by 10.1% from which the vacuum pressure within the evacuated space was determined to have increased from the negligible level of less than 0.1 Pa to 0.16 Pa using the model of Corrucini. Previous research has shown that if the vacuum pressure is less than 0.1 Pa, the effect of conduction through the residual gas on the total glazing heat transfer is negligible. The degradation of vacuum level determined was corroborated by the change in glass surface temperatures.     

Evaluation of phase change materials for thermal regulation enhancement of building integrated photovoltaics

Regulating the temperature of building integrated photovoltaics (BIPV) using phase change materials (PCMs) reduces the loss of temperature dependent photovoltaic (PV) efficiency. Five PCMs were selected for evaluation all with melting temperatures ∼25 ± 4 °C and heat of fusion between 140 and 213 kJ/kg. Experiments were conducted at three insolation intensities to evaluate the performance of each PCM in four different PV/PCM systems. The effect on thermal regulation of PV was determined by changing the (i) mass of PCM and (ii) thermal conductivities of the PCM and PV/PCM system. A maximum temperature reduction of 18 °C was achieved for 30 min while 10 °C temperature reduction was maintained for 5 h at −1000 W/m² insolation.     

Measurement of in-plane thermal conductivity of carbon paper diffusion media in the temperature range of −20 °C to +120 °C

Carbon paper is commonly used as the gas diffusion layer (GDL) in polymer electrolyte membrane (PEM) fuel cells as it exhibits high chemical and mechanical durability. This diffusion medium is also anisotropic, which directly affects its transport properties and specifically the thermal conductivity. In this study, the in-plane thermal conductivity of the carbon paper GDL was determined using thermal diffusivity measurements for a temperature range from −20 to +120 °C and four Teflon loadings (0, 5, 20 and 50 wt.%). It is important to understand the effect of temperature on the thermal conductivity since PEM fuel cells are designed to operate under various temperatures depending on the application of use. Further, Teflon is used to change the hydrophobic properties of the carbon paper GDL with 20 wt.% as the most widely used percentage. In this study, the Teflon loadings were chosen to gain a comprehensive understanding of the thermal resistance due to Teflon. In this study, a quasi-steady method was used to measure the thermal properties of the carbon paper; hence, the phase transformation in the presence of PTFE was investigated. The thermal conductivity decreases with an increase in temperature for all samples. The addition of as little as 5 wt.% Teflon resulted in high thermal resistance decreasing the overall thermal conductivity of the sample. Further addition of Teflon did not have major effects on the thermal conductivity. For all treated samples, the thermal conductivity lies in the range of 10.1–14.7 W/mK. Finally, empirical relations for the thermal diffusivity and conductivity with temperature were deduced.