1.

Phase Change Material Cooling: This technique involves using a material that can

absorb and release heat as it changes from a solid to a liquid or vice versa. The phase

change material is placed in direct contact with the battery cells and absorbs heat as the

battery operates. When the material reaches its melting point, it absorbs large amounts

of heat and maintains the battery temperature within a narrow range.

2. Heat pipes: Heat pipes are used to transfer heat from the battery pack to a remote heat

sink. They consist of a sealed tube containing a liquid that vaporizes at the hot end of

the pipe and condenses at the cool end. Heat pipes are effective at transferring heat

over long distances and can be used to cool battery packs that are located in hard-to-

reach areas.

3. Thermoelectric cooling: This method uses a thermoelectric module to cool the battery

pack. The module consists of two dissimilar materials that are sandwiched together.

When a current is applied to the module, one side becomes cooler and the other side

becomes hotter. Thermoelectric cooling is less efficient than other methods but has the

advantage of being solid-state and quiet. This technique uses the Peltier effect to cool

the battery. A thermoelectric cooler (TEC) is placed in contact with the battery, and when

an electric current is passed through it, one side becomes hot and the other side

becomes cold. The cold side is placed in contact with the battery, and the heat is

dissipated to the surrounding environment.

4. Hybrid Cooling: Hybrid cooling involves using a combination of two or more cooling

techniques to optimize battery cooling. Hybrid vehicles use a combination of an internal

combustion engine and an electric motor to provide propulsion. The battery in a hybrid

vehicle plays a critical role in storing and supplying energy to the electric motor.

Electric vehicles (EVs) require cooling systems to maintain the temperature of their batteries,

electric motors, and power electronics. Overheating can cause battery degradation, motor

malfunctions, and other damage to the vehicle's components.

External cooling is an important aspect of electric vehicles, as it helps to maintain optimal

performance and prevent overheating of critical components such as the battery pack and

electric motor.
There are several external cooling techniques used in EVs:

1. Active aerodynamics: Active aerodynamics is a technique used in some vehicles to

improve their aerodynamic performance and reduce drag. This technique involves

adjusting various components of the vehicle's body, such as flaps or vents, to optimize

airflow over the vehicle. One specific application of active aerodynamics is in cooling

systems. In some vehicles, such as high-performance sports cars, cooling requirements

can be significant due to the high power output of their engines. Active aerodynamics

can be used to enhance the cooling performance of these vehicles by controlling the

flow of air over the cooling system components.

2. Heat exchangers : These are commonly used in many different industries and

applications to transfer heat from one fluid to another. In the context of cooling

techniques for vehicles, heat exchangers are often used to dissipate heat from the

vehicle's engine, transmission, or other components. There are several different types of

heat exchanger cooling techniques used in vehicles, including:

● Air-to-air heat exchangers: This type of heat exchanger transfers heat between two

streams of air. In vehicle cooling systems, air-to-air heat exchangers are often used to

cool intercoolers or charge air coolers, which are used to cool the air entering the

engine.

● Air-to-liquid heat exchangers: This type of heat exchanger transfers heat between air

and a liquid coolant. In vehicle cooling systems, air-to-liquid heat exchangers are often

used to cool the engine, transmission, or other components.

● Liquid-to-liquid heat exchangers: This type of heat exchanger transfers heat between

two streams of liquid. In vehicle cooling systems, liquid-to-liquid heat exchangers are

often used to cool the engine oil, transmission fluid, or other fluids.

● Phase change heat exchangers: This type of heat exchanger uses a refrigerant to

absorb heat from a stream of fluid, causing the refrigerant to evaporate and become a

gas. The gas is then condensed back into a liquid, releasing the heat into the

surrounding environment. Phase change heat exchangers are often used in vehicle
cooling systems to cool refrigerant or other fluids.

● Hybrid heat exchangers: This type of heat exchanger combines two or more of the

above techniques to achieve a specific cooling performance. For example, an air-to-air

heat exchanger may be combined with a liquid-to-liquid heat exchanger to cool both the

engine and intercooler.

METHODOLOGY

Electric vehicles (EVs) require cooling systems to maintain the temperature of their batteries,

electric motors, and power electronics. Overheating can cause battery degradation, motor

malfunctions, and other damage to the vehicle's components. The cooling system methodology

for EVs typically involves the following steps:

1. Designing and cooling system architecture selection: The cooling system architecture

selection depends on the specific application and performance requirements of the

vehicle. There are several different cooling system architectures, including liquid cooling,

air cooling, phase change cooling, and active cooling. The cooling system must be

designed to meet the specific cooling requirements of the vehicle's components.This

involves determining the cooling capacity required for each component and selecting the

appropriate cooling technique.

2. Cooling system component selection: Once the cooling system architecture has been

selected, the next step is to select the specific components for the system, including the

coolant, pump, radiator, heat exchanger, and other components.

3. Thermal management system design: The first step in designing an EV cooling system

is to determine the thermal requirements of the vehicle's components. This includes

calculating the maximum heat dissipation for each component and determining the

required cooling capacity of the system.The temperature of the vehicle's components

must be monitored to ensure they stay within safe operating limits. This is typically done

using temperature sensors that are installed in key locations throughout the vehicle.

4. Component placement and routing: Once the thermal requirements have been
determined, the next step is to determine the best placement of the components and the

routing of the coolant flow, it must be installed in the vehicle. This may involve routing

coolant lines, installing radiators or heat exchangers, and mounting cooling fans or other

components.This may involve designing ducting and airflow channels to optimize the

cooling performance of the system.

5. System integration and testing: The final step in the cooling system methodology for EVs

is to integrate the system into the vehicle and test its performance under various

operating conditions. This includes conducting tests to ensure that the cooling system is

capable of maintaining the required temperatures for each component and ensuring that

the system is reliable and efficient. The cooling system must be controlled to maintain

the desired temperature range for each component. This is typically done using a

controller that adjusts the flow of coolant or airflow based on temperature readings from

the sensors.

6. Maintenance and repairs: The cooling system must be maintained to ensure it continues

to operate effectively. This may involve regular inspections, coolant flushes, and

replacing worn or damaged components.

Overall, the cooling system methodology for EVs is a critical aspect of vehicle design and

operation. Proper cooling is essential for maintaining the performance and longevity of the

vehicle's components, and designers and manufacturers must carefully consider the cooling

requirements of their EVs to ensure optimal performance and safety. The cooling system

methodology for EVs is an important consideration for vehicle designers and manufacturers, as

it plays a critical role in maintaining the temperature of various vehicle components and

optimizing performance and efficiency. The methodology involves several steps, including

thermal management system design, component placement and routing, cooling system

architecture selection, cooling system component selection, and system integration and testing.

Recommendations of cooling systems as per research on Emerging Technologies

1. Microchannel cooling: .Microchannel cooling is a cooling technique that involves the use

of small channels (typically less than 1 mm in diameter) to circulate coolant through a

heat exchanger. The channels are typically etched or machined into a metal or ceramic

plate, and the coolant flows through the channels to remove heat from a component or

system. This technique involves using small channels with high aspect ratios to improve

the heat transfer performance of the cooling system. This technique has been used in

other industries and has the potential to improve the cooling performance of electric

vehicle batteries and power electronics.

Microchannel cooling offers several potential benefits for cooling electric vehicles,

including:

● High cooling performance: Microchannel cooling can provide high cooling performance

due to the large surface area available for heat transfer in the small channels.

● Compact design: The small size of the channels and the heat exchanger can result in a

more compact and lightweight cooling system compared to traditional cooling

techniques.

● Enhanced thermal management: Microchannel cooling can provide more precise

temperature control and can be designed to target specific areas or components in the

vehicle.

● Reduced coolant volume: The small size of the channels can reduce the volume of

coolant required for the cooling system, which can result in lower weight and cost.

However, Microchannel cooling also has some potential drawbacks, including:

● Manufacturing complexity: The manufacturing process for microchannel heat

exchangers can be complex and expensive, which can increase the overall cost of the

cooling system.

● Clogging risk: The small size of the channels can increase the risk of clogging from

debris or contaminants in the coolant, which can reduce the effectiveness of the cooling

system.

2. Nanofluid cooling: Nanofluid cooling is a cooling technique that involves the use of a

coolant that contains nanoparticles, typically with sizes ranging from 1-100 nm. The

nanoparticles are dispersed in a base fluid, such as water or oil, to form a nanofluid that
has enhanced thermal properties compared to the base fluid. Nanofluid cooling involves

adding nanoparticles to the coolant to improve its heat transfer performance. This

technique has shown promise in laboratory tests and could be applied to electric vehicle

cooling systems to improve their cooling efficiency.

Nanofluid cooling offers several potential benefits for cooling electric vehicles, including:

● Enhanced thermal conductivity: The nanoparticles in the coolant can increase the

thermal conductivity of the fluid, which can improve the cooling performance of the

system.

● Reduced coolant volume: The higher thermal conductivity of the nanofluid can enable

the use of lower volumes of coolant, which can result in a more compact and lightweight

cooling system.

● Improved heat transfer: The enhanced thermal properties of the nanofluid can enable

more efficient heat transfer between the components and the coolant, which can

improve the cooling performance of the system.

However, nanofluid cooling also has some potential drawbacks, including:

● Higher cost: The production of nanoparticles and their dispersion in the base fluid can

increase the cost of the coolant compared to traditional coolants.

● Clogging: The nanoparticles can potentially clog the channels or tubes in the cooling

system, which can reduce the effectiveness of the cooling system.

● Corrosion: The nanoparticles in the coolant can potentially cause corrosion of the

cooling system components, which can reduce the durability and reliability of the system.

3. Synthetic jets: Synthetic jet cooling is a type of cooling system that uses oscillating fluid

jets to transfer heat away from a component or system. The system consists of a

chamber filled with a fluid (usually air) and one or more diaphragms that oscillate to

create a series of jets that impinge on the surface of the component being cooled.

Synthetic jets are small devices that produce pulsating airflows. They can be used to
improve the heat transfer performance of heat exchangers by disrupting the boundary

layer and increasing turbulence. Synthetic jets could potentially be applied to electric

vehicle cooling systems to improve their efficiency and reduce their size and weight.

Synthetic jet cooling offers several potential benefits for cooling electric vehicles, including:

● High cooling performance: Synthetic jet cooling can provide high cooling performance

due to the turbulent mixing of the fluid and the surface of the component being cooled,

which can enhance heat transfer.

● Compact design: The synthetic jet cooling system can be designed to be compact and

lightweight, which can reduce the weight and size of the cooling system.

● Low noise: The oscillating diaphragms in the synthetic jet cooling system can produce

lower noise levels compared to traditional cooling techniques that use fans or pumps.

● Low power consumption: The synthetic jet cooling system can consume less power

compared to traditional cooling techniques, which can improve the overall efficiency of

the vehicle.

However, synthetic jet cooling also has some potential drawbacks, including:

● Limited cooling capacity: The cooling capacity of the synthetic jet cooling system may be

limited compared to traditional cooling techniques, which can be a concern in high-

performance applications.

● Complexity: The design and manufacturing of the synthetic jet cooling system can be

complex and require precise control over the oscillation frequency and amplitude.

● Reliability issues: The oscillating diaphragms in the synthetic jet cooling system can

experience fatigue or failure over time, which can impact the reliability of the cooling

system.

4. Active material cooling: Active material cooling is a cooling technique that involves the

use of materials that can actively remove heat from a component or system. The

materials typically use a phase change process, such as melting or solidification, to

absorb or release heat. Active material cooling is a technique using materials that can

absorb and dissipate heat to improve the cooling performance of the system. This
technique has shown promise in laboratory tests and could be applied to electric vehicle

batteries and power electronics to improve their cooling performance.

Active material cooling offers several potential benefits for cooling electric vehicles, including:

● High cooling performance: Active material cooling can provide high cooling performance

due to the large amount of heat that can be absorbed or released during the phase

change process.

● Compact design: The active material cooling system can be designed to be compact and

lightweight, which can reduce the weight and size of the cooling system.

● Improved thermal management: Active material cooling can provide more precise

temperature control and can be designed to target specific areas or components in the

vehicle.

However, active material cooling also has some potential drawbacks, including:

● Limited capacity: The cooling capacity of the active material cooling system may be

limited compared to traditional cooling techniques, which can be a concern in high-

performance applications.

● Limited durability: The active materials can experience degradation over time due to

repeated cycles of phase change, which can impact the reliability of the cooling system.

● Complex design: The design and manufacturing of the active material cooling system

can be complex and require precise control over the phase change process.

5. Thermal storage systems: Thermal storage systems are designed to store thermal

energy for later use, which can be beneficial in cooling applications. In the context of

cooling electric vehicles, thermal storage systems can be used to store excess cooling

capacity during periods of low demand, and then release the stored cooling capacity

during periods of high demand. Thermal storage systems can store excess heat

generated by the vehicle's components and release it later when needed. Using thermal

storage systems in cooling systems could potentially reduce the need for active cooling

and improve the efficiency of the vehicle's cooling system.

There are several types of thermal storage systems that can be used for cooling electric

vehicles, including:

➔ Ice storage systems: Ice storage systems use water as a thermal storage medium and

freeze it during periods of low demand. The stored ice can then be used to cool the

vehicle during periods of high demand.

➔ Thermochemical storage systems: Thermochemical storage systems use chemical

reactions to store and release thermal energy. The system typically involves a reversible

chemical reaction that can absorb or release heat.

Thermal storage systems offer several potential benefits for cooling electric vehicles, including:

● Improved efficiency: Thermal storage systems can help to improve the overall efficiency

of the cooling system by storing excess cooling capacity and releasing it later during

periods of high demand.

● Reduced energy consumption: Thermal storage systems can reduce the energy

consumption of the cooling system by allowing it to operate at lower power during

periods of low demand.

● Reduced component wear: Thermal storage systems can reduce the wear and tear on

the components of the cooling system by reducing the frequency of on/off cycling.

However, thermal storage systems also have some potential drawbacks, including:

● Limited capacity: The capacity of thermal storage systems may be limited, which can be

a concern in high-performance applications.

● Complexity: The design and implementation of thermal storage systems can be complex

and require careful consideration of the materials, components, and control systems.

6. Direct immersion cooling: Direct immersion cooling is a cooling technique that involves

immersing the components of an electric vehicle, such as the battery pack or power

electronics, directly into a cooling fluid. This allows for efficient heat transfer from the

components to the cooling fluid, which can then be circulated to a heat exchanger for
dissipation.

In a direct immersion cooling system for an electric vehicle, the components are typically

enclosed in a container or enclosure that is filled with a dielectric cooling fluid, such as a

fluorocarbon or mineral oil. The cooling fluid is circulated through the container using a

pump or other means, and heat is transferred from the components to the cooling fluid.

Direct immersion cooling offers several potential benefits for cooling electric vehicles, including:

● High cooling capacity: Direct immersion cooling can provide high cooling capacity and

can be used to cool multiple components simultaneously.

● Reduced noise: Direct immersion cooling can reduce the noise generated by the cooling

system, as there are no fans or pumps required.

● Improved efficiency: Direct immersion cooling can improve the efficiency of the cooling

system by reducing the thermal resistance between the components and the coolant.

However, direct immersion cooling also has some potential drawbacks, including:

● Increased complexity: Direct immersion cooling can increase the complexity of the

cooling system, as it requires the components to be designed for immersion in the

coolant.

● Safety concerns: Direct immersion cooling requires the use of a non-conductive coolant

to avoid short circuits, which can create safety concerns in case of coolant leakage.

● Cost: Direct immersion cooling can be more expensive than other cooling techniques, as

it requires a specialized coolant and may require modifications to the components.