Novel battery thermal management via scalable dew-point evaporative cooling

Thermal management is critical to safety, stability, and durability of battery energy storage systems. Existing passive and active air cooling are not competent when the cooling performance, energy efficiency and cost of the thermal management system are drawing concurrent concerns. Here we propose dew-point evaporative cooling as a novel active air-cooling approach for large battery systems. Its capability of cooling the air towards its dew-point temperature with simple working principle and great electrical efficiency offers an ideal solution. Therefore, a scalable dew-point evaporative cooling technology was developed, and a large-scale cooler was constructed which could deliver 2.9–6.7 kW cooling capacity with 8.9–28.9 coefficient of performance (COP). To demonstrate its performance for battery thermal management, we took a 20 Ah lithium iron phosphate (LFP) prismatic pouch cells for a case study whose complex dynamic electrochemical and thermal responses were investigated via lock-in thermography experiments and electrochemical-thermal modeling. The potential of dew-point evaporative cooling for battery cooling was explored via the multi-physics coupling of battery and cooler models. This study elucidates that dew-point evaporative cooling can efficiently cool a battery by 3.0–13.6 °C lower than the cases with only forced convection, and control the battery operating temperature within an ideal operating range of 20–40 °C.