Performed 3Delectrochemical-thermal modeling of four battery cooling methods 2)Thermal performance of direct air cooling, direct liquid cooling, indirect (jacket) liquid and fin coolingare compared 3) Merits and limitations of each cooling method for occupying a fixed volume are summarized 4) Temperaturerise for a fixed load is lower with direct or indirect liquid cooling lower than air and fin cooling. Abstract Choosing a proper cooling method for a lithium-ion (Li-ion) battery pack for electric drive vehicles (EDVs) and making an optimal cooling control strategy to keep the temperature at a optimal range of 15°C to 35°C is essential to increasing safety, extending the pack service life, and reducing costs. When choosing a cooling method and developing strategies, trade-offs need to be made among many facets such as costs, complexity, weight, cooling effects, temperature uniformity, and parasitic power. This paper considers four cell-cooling methods: air cooling, direct liquid cooling, indirect liquid cooling, and fin cooling. To evaluate their effectiveness, these methods are assessed using a typical large capacity Li-ion pouch cell designed for EDVs from the perspective of coolant parasitic power consumption, maximum temperature rise, temperature difference in a cell, and additional weight used for the cooling system. We use a state-of-the-art Li-ion battery electro-chemical thermal model. The results show that under our assumption an air-cooling system needs 2 to 3 more energy than other methods to keep the same average temperature; an indirect liquid cooling system has the lowest maximum temperature rise; and a fin cooling system adds about 40% extra weight of cell, which weighs most, when the four kinds cooling methods have the same volume. Indirect liquid cooling is more practical form than direct liquid cooling though it has slightly lower cooling performance.

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A battery model that has the capability of analyzing the internal non-uniformity of local state variables, including the state of charge (SOC), temperature and current density, is proposed in this paper. The model is built using a set of distributed parameter equivalent circuits. In order to validate the accuracy of the model, a customized battery with embedded T-type thermocouple sensors inside the battery is tested. The simulated temperature conforms well with the measured temperature at each test point, and the maximum difference is less than 1°C. Then, the model is applied to analyze the evolution processes of local state variables' distribution inside the battery during the discharge process. The simulation results demonstrate drastic distribution changes of the local state variables inside the battery during the discharge process. The internal non-uniformity is originally caused by the resistance of positive and negative foils, while also influenced by the change rate of open circuit voltage and the total resistance of the battery. Hence, the factors that affect the distribution of the local state variables are addressed.

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