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Battery pack cooling using Thermal pads vs Phase change material.

When it comes to battery pack cooling in electric vehicles, both thermal pads and phase change materials (PCMs) can be used, each with its advantages and considerations. Let's explore the characteristics of both options:

Thermal Pads:



Thermal pads are typically made of a soft, compressible material filled with thermally conductive particles, such as silicone-based materials. They are commonly used for thermal interface applications in electronic devices, including battery pack cooling. Here are some key points to consider:

  1. Thermal Conductivity: Thermal pads have moderate to high thermal conductivity, allowing them to efficiently transfer heat between the battery cells and cooling system.

  2. Compressibility: Thermal pads are flexible and compressible, conforming to the uneven surfaces of battery cells and heat sinks, ensuring good contact and minimizing air gaps for improved heat transfer.

  3. Ease of Installation: Thermal pads are easy to install, as they can be cut to fit different shapes and sizes. They can be placed between the battery cells and heat sink or other cooling components without requiring additional adhesives.

  4. Limited Reusability: Once compressed and used, thermal pads may lose their original thickness and may not be reusable. Replacement or readjustment might be necessary during maintenance or repairs.


Phase Change Materials (PCMs):



PCMs are substances that can store and release thermal energy by changing their phase (solid to liquid or liquid to solid) within a specific temperature range. In battery pack cooling, PCMs are often incorporated into heat sink structures or modules. Here are some considerations for PCMs:

  1. High Heat Capacity: PCMs have high heat capacity, which allows them to absorb and store large amounts of heat during the phase change process, thereby buffering temperature spikes in the battery pack.

  2. Passive Cooling: PCMs can provide passive cooling benefits as they absorb heat from the battery cells and release it when the temperature drops. This can help reduce the reliance on active cooling systems, potentially improving energy efficiency.

  3. Limited Heat Transfer Rate: The thermal conductivity of PCMs is generally lower than that of thermal pads. While PCMs can absorb heat effectively, the rate at which they transfer heat to external cooling systems might be slower.

  4. PCM Selection: The choice of PCM is crucial, as it should have a suitable phase change temperature range to match the desired operating temperatures of the battery pack. Different PCMs have different melting and solidification temperatures.

In practice, a combination of thermal pads and PCMs can be used in battery pack cooling systems. Thermal pads can provide direct heat transfer between battery cells and cooling components, while PCMs can act as thermal buffers to manage temperature fluctuations and reduce the load on active cooling systems.

It's important to evaluate the specific requirements of the battery pack cooling system, including temperature targets, available space, and system complexity, to determine the most appropriate solution or combination of solutions. Consulting with battery pack cooling experts or thermal management specialists can provide valuable insights for optimising the cooling strategy for your specific application.


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