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This paper presents a thermal interface for cylindrical cells using busbar-integrated cooling channels. This interface is available due to the use of a stand-alone refrigerant circuit for the thermal management of the battery. A stand-alone refrigerant circuit offers performance and efficiency increases compared to state-of-the-art battery thermal management systems. This can be achieved by increasing the evaporation temperature to the requirements of the Li-ion cells and the use of alternative refrigerants. The solution proposed in this paper is defined for electric two-wheelers, as the thermal management of these vehicles is currently insufficient for fast charging where high heat losses occur. Three channel patterns for the integrated busbar cooling were examined regarding their thermal performance to cool the li-ion cells of a 16p14s battery pack during fast charging. A method of coupling correlation-based heat transfer and pressure drop with thermal finite element method (FEM) simulations was developed. The symmetric channel pattern offers a good compromise between battery temperatures and homogeneity, as well as the best volumetric and gravimetric energy densities on system level. Average cell temperatures of 22 °C with a maximum temperature spread of 8 K were achieved.

Stand-Alone Battery Thermal Management for Fast Charging of Electric Two Wheelers—Integrated Busbar Cooling