Why do EV battery packs need a cooling system?

April 30, 2021April 30, 2021 John Carey 15195 Views EV battery pack cooling, EV battery pack thermal management

There are a bunch of inter-related reasons to control the temperature of an EV’s battery pack. While cooling is crucial, warming can also be important.

The safety, service life, storage capacity and charging speed of a lithium-ion battery pack are all temperature dependent, so it’s really desirable to keep its cells working in a fairly tight range between about 20 and 40 degrees C.

What happens if you don’t? Good question…

Fire is the headline hazard. Every owner of a mobile phone or laptop computer will have noticed their device gets warm, maybe even hot, when it’s being charged. EVs are no different, but there’s a lot more heat to deal with.

How much more? Here’s a useful comparison. What you’re reading right now is being written on a MacBook Pro. My laptop’s bottom gets quite toasty when its battery is being charged. The battery pack of last EV I drove, a Leaf e+, stores roughly 1000 times more energy.

Batteries and battery packs also heat up when continually discharging at high rates.

Letting the heat build up is dangerous. Though the threshold temperature varies somewhat among the different lithium-ion cell chemistries, at around 140 degrees C a process called “thermal runaway” occurs.

What this means is that the cell gets hotter and hotter, and nothing can be done to stop the process. This can lead to the cell catching fire or bursting.

Cutaway diagram showing the battery pack and cooling system of an Audi e-Tron — Staying cool with lithium-ion batteries: The battery pack and cooling system of an Audi e-Tron

Disaster! Which is why automotive battery packs combine sensors and software into a complex management system to constantly monitor temperature and other key operational parameters.

There are other reasons why heat is undesirable in a battery pack. Cell aging processes are accelerated by heat, so temperature control is a key factor for ensuring the battery pack has the longest possible useful life.

Battery pack temperature also influences charging speed. Remember that the cells in the pack heat up when they’re being charged. Serious amounts of heat can be generated when charging quickly, as at a DC fast charger. Without a cooling system to carry this heat away, the only way to protect the battery pack is to reduce the charging rate; that’s also why the car will adjust its charging rate depending on the temperature and state of charge (SOC).

There are consequences if a battery pack gets too cold, too. Low temperatures greatly reduce the amount of energy a lithium-ion cell can store. This, in turn, means a lot less driving range.

Thermal management is what engineers call keeping the battery pack in its comfort zone. There are different ways to ensure the cells remain in the just-right range between too hot and too cold.

Liquid cooling is the most popular solution with EV manufacturers. This involves pumping coolant (which needs to be replaced through regular servicing) through pipes or plates built into the battery pack, where heat is collected, and then through a radiator, where the heat is dissipated.

Refrigerant-based systems are sometimes used, but rarely. These work on the same principle as a car’s air-conditioning system, by circulating a refrigerant gas through pipes around the battery pack, a radiator and a compressor. And like reverse-cycle air-con, they can also be used to heat the pack, something that’s a bit more difficult with other systems.

Cutaway diagram of an Audi e-Tron GT showing the cooling system for the lithium-ion battery pack

Air cooling is simpler and cheaper, but because air cannot carry as much heat as a liquid coolant it’s also the least effective. The most basic set-ups simply let the air circulate around or through the battery pack. Adding a fan to increase flow improves effectiveness, as does using the air-con system to chill air before puffing it through the pack.

The Nissan Leaf is the best-known example of an EV with an air-cooled battery pack, but the Renault Zoe is another.

Early versions of the big-selling Nissan proved prone to premature battery pack aging in hot climates. Some owners also found DC fast-charging rates could be slowed way down when the battery pack temperature rose high enough to ring management system alarm bells.

Although the battery pack of the latest Leaf e+ has so far been trouble-free, Nissan’s earlier problems mean that air-cooled battery packs have a bad reputation with the EV community.

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John Carey

Grew up in country NSW, way back when petrol was laced with lead. Has written about cars and the car business for more than 35 years, working full-time and freelance for leading mags, major newspapers and websites in Australia and (sometimes) overseas. Avidly interested in core EV technologies like motors and batteries, and believes the switch to electromobility definitely should be encouraged. Is waiting patiently for someone to make a good and affordable EV that will fit inside his tiny underground garage in northern Italy, where he's lived for the past decade. Likes the BMW i3, but it's just too damned wide...