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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

High-heat transfer lithium-ion batteries: A new era in battery thermal management

Despite advances in lithium-ion battery technology, critical challenges remain that must be addressed to accelerate electric vehicle (EV) adoption and global energy transformation. Significantly improved battery thermal management (BTM) is key to overcoming these challenges. BTM approaches focus on increasing heat transfer coefficients via air, liquid, or refrigerant cooling, but less attention is given to reducing the battery's thermal resistance, a major bottleneck for heat transfer. This work introduces a novel approach to reduce battery thermal resistance by integrating in-plane heat transfer with optimized cell geometry, minimized thermal resistances, and reduced interfacial resistances, representing a departure from previous methods. The standard prismatic can cell incorporating this technology is referred to as the high heat transfer (HHT) battery. An equivalent resistance battery thermal model is developed for speed and accuracy, validated against experimental data in the literature, demonstrating strong correlation and ensuring reliable predictions for real-world performance. Thermal performance metrics of the conventional and HHT batteries are compared using a parametric study with air, liquid, and refrigerant boundary conditions across a range of aspect ratios. The HHT battery shows a heat removal rate up to 20 times higher than a conventional battery. These findings suggest that HHT technology could be transformative for EV battery performance, enabling fast charging, mitigating thermal runaway, extending battery life, reducing cold-weather power loss, increasing reliability, lowering costs, and enabling higher energy density, all critical for EV adoption and energy transformation. Future work will focus on prototyping and real-world testing to refine these findings for commercial-scale applications.

25 ENERGY STORAGE↗
DOE OSTI2020

The Role of Interfacial Thermal Resistance in Li-Ion Battery Thermal Management: Preprint

Temperature critically affects the performance, life and safety of lithium-ion batteries. Therefore, it is essential to understand heat generation and dissipation within individual battery cells and battery packs to plan a proper thermal management strategy. One of the key challenges is that interfacial heat transfer of a battery unit is difficult to quantify. The steady-state absolute method and the transient laser-flash-diffusivity method were employed to measure heat conductivities of battery layer stacks and individual battery layer separately. Results show flash diffusivity method gives higher thermal conductivity at both cross-plane and in-plane directions. The difference is primarily caused by interfacial thermal resistance so that it can be estimated by steady-state and transient measurements. To investigate the effects of interfacial thermal transport beyond individual cell level, a multiphysics battery model is used. The model is built upon a multi-scale multi-domain modeling framework for battery packs that accounts for the interplay across multiple physical phenomena. Benefits of a battery module using thermal management materials are quantified through numerical experiments. During a thermal runaway event, it is found interfacial thermal resistance can mitigate thermal runaway in a battery module by significantly reducing heat transfer between cells.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Technology Evaluation of the Yotta SolarLEAF: A Panel-Based Thermally Managed Battery Module

In 2019, the United States installed 13.3 gigawatts of solar energy production capacity. This demand for solar will continually increase as the phasing out of fossil fuels continue. As the demand for solar energy grows, so does the demand to store this generated energy. It is projected that by 2035 the global demand for stationary energy storage will reach the terawatt scale. So, scalable solutions with suitable thermal management systems are required to meet future demand. Yotta Solar has developed an ESS system, the Yotta LEAF, that provides solar energy storage without increasing the footprint of solar arrays. This is particularly useful in applications with limited space (e.g., building roof) and where large scale batteries require strong requirements for fire suppression systems. As part of the Wells Fargo Innovation Incubator (IN2), the National Renewable Energy Laboratory (NREL) has conducted a third-party technology validation of Yotta's alpha prototype. The report includes the objectives, technology description, methodology, and results from experiments conducted at the Thermal Transfer Facility (TTF) at NREL.

14 SOLAR ENERGY↗
DOE OSTI2024

Li-Ion Battery Thermal Characterization for Thermal Management Design

Battery design efforts often prioritize enhancing the energy density of the active materials and their utilization. However, optimizing thermal management systems at both the cell and pack levels is also key to achieving mission-relevant battery design. Battery thermal management systems, responsible for managing the thermal profile of battery cells, are crucial for balancing the trade-offs between battery performance and lifetime. Designing such systems requires accounting for the multitude of heat sources within battery cells and packs. This paper provides a summary of heat generation characterizations observed in several commercial Li-ion battery cells using isothermal battery calorimetry. The primary focus is on assessing the impact of temperatures, C-rates, and formation cycles. Moreover, a module-level characterization demonstrated the significant additional heat generated by module interconnects. Characterizing heat signatures at each level helps inform manufacturing at the design, production, and characterization phases that might otherwise go unaccounted for at the full pack level. Further testing of a 5 kWh battery pack revealed that a considerable temperature non-uniformity may arise due to inefficient cooling arrangements. To mitigate this type of challenge, a combined thermal characterization and multi-domain modeling approach is proposed, offering a solution without the need for constructing a costly module prototype.

25 ENERGY STORAGE↗
DOE OSTI2022

A Comprehensive Numerical and Experimental Study for the Passive Thermal Management in Battery Modules and Packs

Cooling plates in battery packs of electric vehicles play critical roles in passive thermal management systems to reduce risks of catastrophic thermal runaway. In this work, a series of numerical simulations and experiments are carried out to unveil the role of cooling plates (both between cells and a bottom plate parallel to the cell stack) on the thermal behavior of battery modules and packs under nail penetrations. First, we investigated the role of side cooling plates on the thermal runaway propagation mitigation in battery modules (1S3P) and packs (3S3P) by varying the key parameters of the side cooling plates, such as plate thicknesses, thermal contact resistances, and materials. Then, three important factors for passive thermal management systems are identified: (i) thermal mass of side cooling plates, (ii) interfacial thermal contact resistances, and (iii) the effective heat transfer coefficients at exterior surfaces. The roles of bottom cooling plates on thermal runaway propagation mitigation in 1S3P and 1S5P battery modules are numerically investigated by comparing the thermal behavior of the modules with only side cooling plates and with both side and bottom cooling plates.

25 ENERGY STORAGE↗
DOE OSTI2021

A review of thermal physics and management inside lithium-ion batteries for high energy density and fast charging

Traditionally it has been assumed that battery thermal management systems should be designed to maintain the battery temperature around room temperature. That is not always true as lithium-ion battery (LIB) R&D is pivoting towards the development of high energy density and fast charging batteries. Therefore, it is necessary to have a comprehensive review of thermal considerations for LIBs targeted for high energy density and fast charging, i.e., the optimal thermal condition, thermal physics (heat transport and generation) inside the battery, and thermal management strategies. As the energy density and charge rate increases, the optimal battery temperature can shift to be higher than room temperature. In the first part of the review various sources of heat generation inside LIBs and various approaches to minimizing battery heat generation are summarized. The importance of heat of mixing due to ion diffusion during fast charging is also highlighted. To improve the temperature uniformity and avoid excessive internal temperature rise, heat transfer inside the battery needs to be enhanced, and reducing the thermal contact resistance between the electrodes and separator can significantly increase the effective thermal conductivity of batteries. In the second part of the review various challenges and latest developments related to thermal transport and properties of LIBs are discussed. Finally, a summary of latest advancement on smart control of internal temperature of LIBs is discussed as depending on the ambient temperature and the optimal temperature; the battery heat needs to be retained or dissipated to elevate or avoid temperature rise.

25 ENERGY STORAGE↗
DOE OSTI2021

Effect of thermal environments on fast charging Li-ion batteries

Battery thermal management systems (BTMSs) are expected to keep the battery temperature at a moderate level (~30 °C) to minimize the thermally exacerbated degradation. However, during fast charging, a strong cooling system is required to restrict the temperature rise of Li-ion batteries (LiBs), which significantly increases the cost and weight of battery packs, and induces a large temperature variation inside the battery. Here, in this work, we find that all these drawbacks could be relieved by allowing LiBs to charge at higher temperatures. Since the fast charging of a LiB only takes a tiny fraction of its lifetime, the aging rate is limited even at a charging temperature of 60 °C. Three types of thermal environments are proposed: kept constant at 30 °C, preheated to 60 °C, and adiabatic fast charging. With an experimentally validated electrochemical-thermal (ECT) coupled model, we explore the interplay between thermal management and the fast-charging performance. It is found that a gradually increasing temperature profile is the best option to balance the lithium plating and thermal management of the battery. Combining adiabatic fast charging with a preheating step, we can achieve minimal cooling need, perfect temperature uniformity within a battery, and fast-charging capability simultaneously.

25 ENERGY STORAGE↗
DOE OSTI2026

A Novel and Scalable Method for Microencapsulating Salt Hydrate Phase Change Materials in Core–Shell Fibers

Phase change materials (PCMs) are in high demand for applications such as thermal energy storage in buildings, electronics cooling, and thermal management of electric vehicle batteries and data centers. Among these materials, salt hydrate PCMs are particularly attractive due to their high thermal energy storage capacity and low cost. However, they suffer from two major issues: leakage in the melted phase and phase segregation during phase transitions. Microencapsulation is the primary process capable of addressing both of these challenges. However, there is no reliable or scalable method available for microencapsulating salt hydrate PCMs. As a result, the full potential of salt hydrates for building and data center applications has yet to be realized. In this work, we present an innovative method for the microencapsulation of salt hydrate PCMs using a co‐axial pushing technique. This process creates core–shell fibers, with the salt hydrate as the core and a polymer as the shell. Our approach demonstrates strong potential for scalable microencapsulation of salt hydrate PCMs. In conclusion, achieving scalability could enable their widespread use in applications such as data center cooling, battery thermal management, and building climate control.

Sharma, Jaswinder [Oak Ridge National Laboratory (↗
DOE OSTI2023

Estimate long-term impact on battery degradation by considering electric vehicle real-world end-use factors

Many estimates of battery capacity degradation are based on accelerated lab tests that involve charge-discharge cycles or rely on data or electrochemical modeling. These methods are reasonable for technology benchmarking but rarely consider real-world end-use factors. To address this issue, this study develops the Battery Run-down under Electric Vehicle Operation (BREVO) model. It links the driver's travel pattern to physics-based battery degradation and powertrain energy consumption models. The model simulates the impacts of charging behavior, charging rate, driving patterns, and multiple energy management modules on battery capacity degradation. It finds that, over a 10-year timespan, firstly, for a random driver situated in the New England area, daily direct-current fast charging (60 kW) could lead to up to 22% less battery capacity when compared to daily Level-1 charging (1.8 kW). Second, the battery thermal management system can delay battery degradation by approximately 0.5% in the New England area. Third, warmer ambient temperatures enhance BEV battery usage. The model indicates that the battery capacity in the Los Angeles area is 6% higher than that in the New England area. The BREVO model provides crucial information for consumers and BEV manufacturers on range anxiety, BEV battery design, and decision support of battery warranty.

25 ENERGY STORAGE↗
DOE OSTI2023

Thermal regulation of batteries

A battery thermal management system for an air vehicle includes a first heat exchange circuit, a battery in thermal communication with the first heat exchange circuit, and a heat exchanger positioned on the first heat exchange circuit. The heat exchanger is operatively connected to a second heat exchange circuit. The system includes a controller operatively connected to the second heat exchange circuit. The controller is configured to variably select whether heat will be rejected to the second heat exchange circuit. A method for controlling a thermal management system for an air vehicle includes determining an expected fluid temperature of fluid in a fluid heat exchange circuit. The method includes commanding a flow restrictor at least partially closed or commanding the flow restrictor at least partially open.

Macdonald, Malcolm↗
DOE OSTI2023

Thermal regulation of batteries

A battery thermal management system for an air vehicle includes a liquid heat exchange circuit. The system includes at least one battery in thermal communication with the liquid heat exchange circuit. The system includes a controller operatively connected to the liquid heat exchange circuit. The controller is configured and adapted to variably select whether heat will be rejected to the liquid heat exchange circuit. The system includes at least one heat exchanger positioned on the liquid heat exchange circuit. The at least one heat exchanger is a liquid-air heat exchanger or a liquid-liquid heat exchanger. A method for controlling a thermal management system for an air vehicle includes determining an expected temperature of at least one battery, and cooling the at least one battery with a cooling device if the expected temperature exceeds a pre-determined expected temperature threshold.

Rheaume, Jonathan↗
DOE OSTI2025

Effects of ambient temperature on electric vehicle range considering battery Performance, powertrain Efficiency, and HVAC load

Here, this study investigates the impact of ambient temperature on the range of electric vehicles (EVs) by analyzing its effects on usable battery energy (UBE), heating, ventilation, and air conditioning (HVAC) energy consumption, and powertrain energy losses. Chassis dynamometer tests within a thermal chamber were conducted under various temperature conditions to investigate these impacts. The results indicate that lower temperatures lead to a decrease in UBE for lithium-ion batteries in EVs. At −18 °C, the UBE exhibited reductions of 4---8 % compared to the UBE at 22 °C. Battery thermal management strategies significantly affected the UBE loss, with different strategies resulting in distinct UBE reductions. HVAC energy consumption, especially for interior heating, proved to be the most dominant variable affecting EV driving range. Larger discrepancies between the HVAC target temperature (22 °C) and the ambient temperature increased HVAC energy usage. The type of HVAC system also influenced energy consumption, where EVs equipped with heat pumps demonstrated lower energy consumption for heating compared to those relying solely on resistance heaters. Ambient temperature also influenced motor energy consumption due to increased frictions, powertrain losses and tire rolling resistance at lower temperatures; consequently, regenerative braking energy decreased in cold conditions. Combining these effects influenced the overall energy consumption and driving range of EVs. At −18 °C, the driving range saw a substantial decrease of up to 60 % compared to 22 °C, while a slight decrease was observed at 35 °C.

Ambient Temperature↗
DOE OSTI2020

Long-Term Vehicle Speed Prediction via Historical Traffic Data Analysis for Improved Energy Efficiency of Connected Electric Vehicles

Connected and automated vehicles (CAVs) are expected to provide enhanced safety, mobility, and energy efficiency. While abundant evidence has been accumulated showing substantial energy saving potentials of CAVs through eco-driving, traffic condition prediction has remained to be the main challenge in capitalizing the gains. The coupled power and thermal subsystems of CAVs necessitate the use of different speed preview windows for effective and integrated power and thermal management. Real-time vehicle-to-infrastructure (V2I) communications can provide an accurate speed prediction over a short prediction horizon (e.g., 30 s to 60 s), but not for a long range (e.g., over 180 s). Therefore, advanced approaches are required to develop detailed speed prediction for robust optimization-based energy management of CAVs. This paper presents an integrated speed prediction framework based on historical traffic data classification and real-time V2I communications for efficient energy management of electrified CAVs. The proposed framework provides multi-range speed predictions with different fidelity over short and long horizons. The proposed multi-range speed prediction is integrated with an economic model predictive control (MPC) strategy for the battery thermal management (BTM) of connected and automated electric vehicles (EVs). The simulation results over real-world urban driving cycles confirm the enhanced prediction performance of the proposed data classification strategy over a long prediction horizon. Despite the uncertainty in long-range CAVs’ speed predictions, the vehicle-level simulation results show that 14% and 19% energy savings can be accumulated sequentially through eco-driving and BTM optimization (eco-cooling), respectively, when compared with normal driving (i.e., human driver) and conventional BTM strategy.

Engineering↗
DOE OSTI2023

Extreme fast charging of commercial Li-ion batteries via combined thermal switching and self-heating approaches

Abstract The mass adoption of electric vehicles is hindered by the inadequate extreme fast charging (XFC) performance (i.e., less than 15 min charging time to reach 80% state of charge) of commercial high-specific-energy (i.e., >200 Wh/kg) lithium-ion batteries (LIBs). Here, to enable the XFC of commercial LIBs, we propose the regulation of the battery’s self-generated heat via active thermal switching. We demonstrate that retaining the heat during XFC with the switch OFF boosts the cell’s kinetics while dissipating the heat after XFC with the switch ON reduces detrimental reactions in the battery. Without modifying cell materials or structures, the proposed XFC approach enables reliable battery operation by applying <15 min of charge and 1 h of discharge. These results are almost identical regarding operativity for the same battery type tested applying a 1 h of charge and 1 h of discharge, thus, meeting the XFC targets set by the United States Department of Energy. Finally, we also demonstrate the feasibility of integrating the XFC approach in a commercial battery thermal management system.

25 ENERGY STORAGE↗
DOE OSTI2024

Multi-range vehicle speed prediction using vehicle connectivity for enhanced energy efficiency of vehicles

An integrated speed prediction framework based on historical traffic data mining and real-time V2I communications for CAVs. The present framework provides multi-horizon speed predictions with different fidelity over short and long horizons. The present multi-horizon speed prediction is integrated with an economic model predictive control (MPC) strategy for the battery thermal management (BTM) of connected and automated electric vehicles (EVs) as a case study. The simulation results over real-world urban driving cycles confirm the enhanced prediction performance of the present data mining strategy over long prediction horizons. Despite the uncertainty in long-range CAV speed predictions, the vehicle level simulation results show that 14% and 19% energy savings can be accumulated sequentially through eco-driving and BTM optimization (eco-cooling), respectively, when compared with normal-driving and conventional BTM strategy.

Amini, Mohammad Reza↗
DOE OSTI2020

Review—Thermal Safety Management in Li-Ion Batteries: Current Issues and Perspectives

Approaches for thermal management of lithium-ion (Li-ion) batteries do not always keep pace with advances in energy storage and power delivering capabilities. Root-cause analysis and empirical evidence indicate that thermal runaway (TR) in cells and cell-to-cell thermal propagation are due to adverse changes in physical and chemical characteristics internal to the cell. However, industry widely uses battery management systems (BMS) originally designed for aqueous-based batteries to manage Li-ion batteries. Even the "best" BMS that monitor both voltage and outside-surface temperature of each cell are not capable of preventing TR or TR propagation, because voltage and surface-mounted temperature sensors do not track fast-emerging adverse events inside a cell. Most BMS typically include a few thermistors mounted on select cells to monitor their surface temperature. Technology to track intra-cell changes that are TR precursors is becoming available. Simultaneously, the complex pathways resulting in cell-to-cell TR propagation are being successfully modelled and mapped. Innovative solutions to prevent TR and thermal propagation are being advanced. These include modern BMS for rapid monitoring the internal health of each individual cell and physical as well as chemical methods to reduce the deleterious effects of rapid cell-to-cell heat and material transport in case of TR.

25 ENERGY STORAGE↗