Preliminary assessment of a two-phase direct cooling of Lithium-Ion battery pack for e-bike mobility

Electric mobility is playing an increasingly central role in emission reduction policies to mitigate climate change effect. During the operation of electric vehicles, the batteries may be subject to high variation of the required current, which can lead to a sudden increase in the cell temperature. If this condition occurs repeatedly, there would be a reduction in battery capacity and useful life, and autonomy reduction of the electric vehicle. In the worst case, this problem can lead to the thermal runaway. Therefore, cooling of electric vehicle propulsion systems is a fundamental issue for the electric mobility development. In this article we propose an innovative cooling system using a dielectric low boiling fluid in which the batteries are directly immersed. The system was tested on an electric bicycle under real operative conditions. A special test bench was realized, consisting of a real electric bicycle, a training roller to simulate the load due to road slope and an external electric motor to simulate the pedaling of the cyclist. The results show a substantial decrease in the temperature of the cells with the proposed cooling system and there was a marked improvement in the temperature uniformity of the cells inside the battery pack.