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Base Guide To EV Battery Cooling

Views: 20     Author: Site Editor     Publish Time: 2022-07-29      Origin: Site


You may notice that Electric Vehicles do not have grilles; even those with them barely use them for any purpose rather than design purposes. This is because they lack the issue of overheating.


But an Electric Vehicle's battery, which is the powerhouse of the vehicle, produces heat. Usually, batteries have heat because constant storing and giving out of electricity is done, and heat arises. That heat must be cooled to ensure durability and safety.


Why then is a grille not used to cool EV batteries?

A grille is used to draw air into a vehicle's engine, and even though it might be used to cool batteries, they do not provide maximum satisfaction. This brings about the method of cooling EV batteries called Thermal Management.


Thermal Management works to cool EV batteries with air and with liquid which gets to the exact point to be reached and works better than air.


This article provides details about the various EV battery cooling methods available.

EV Battery Cooling-1

EV Battery Cooling Methods

The following methods are the primary methods for cooling EV batteries.

Active Air-Cooling

In this method, the air is supplied to the battery pack to cool it. The air present in the vehicle is the one circulated through the battery pack to cool it.


Air is also used to cool batteries by the grille. The grille channels air through its duct into the pack to cool the battery.


● The advantage of using air to cool batteries is that it works to some extent.

● In vehicles where medium or low power applications are used, it's sufficient since not much power is consumed, and the battery temperature stays around the environment temperature.

● Occasional high-power demands can be facilitated with the air cooling method as batteries have enough time to cool after high demand.


● The downside to using the air available in the vehicle to cool its battery is that the battery will be heated in some situations. When the environment is too cold, and you turn on the heat in the vehicle, the battery will be heated.


● Also, when the air coming in through the duct is the cooling method for batteries, they may be in inconsistency as their temperature is based on the external environment's temperature.

Liquid Cooling

Liquid cooling involves cooling batteries with a liquid in the battery pack. In this system, the motor and controller are cooled by a separate cooling system with the battery due to the difference in their temperature.


● This is the ideal cooling method for EV batteries.

● The low-power application will nurse the battery to the correct state.

● In high-power applications, the cooling system cools the battery pack maximum.

● Cooling can be upgraded by upgrading the cooling components.


● More effort in the cooling system to keep it low always.

Cooling Methods Over Time

Some 11 years ago, to make a battery that is actively cooled would be expensive due to the expensiveness of batteries. Manufacturers tended to implement passive air cooling when EVs started, to minimize production costs and maximize profit.


Since today batteries are cheaper and easier to get, active cooling is in adamant use as liquids can conduct heat thrice faster than air. Furthermore, rapid charging of Electric vehicles creates constant heat that needs optimized cooling.

EV Battery Cooling

Why EV Batteries Need to Be Cooled

A specific range of temperature is standard for EV batteries to operate on. However, the ambient temperature for the batteries to run on is a range of 20°c(68F) to 25°c(77F), but they might withstand a working temperature of up to 50°c down to -30°c. While charging, the limit tolerance is a temperature of about 0°c to 50°c. 


When the battery is in work and exceeds the working 25°c temperature, the battery pack is destroyed as a result of the chain reaction which takes place. This makes it very important to cool the battery down.


Also, when rapidly charged, the temperature must be cooled down to maintain the 0 to 50°c range to prevent the battery from overheating due to the high current going into it.


When the battery is too low in temperature, it's heated up to keep operations smooth.

Thermal Management Challenges

Even the best practices have downsides. The cooling management services (liquid cooling) have disadvantages absent in the air cooling system. Such as:


This problem caused by holes or breakage in the liquid pipes as a result of age. This can damage the battery performance significantly and cause it to cease functioning when electrical components correlate with liquid.


Constant water with air causes corrosion. The liquid cooling is vulnerable to this problem when liquid ages. You can avoid constantly changing liquid glycol.


The channels or pipes where liquid travels tend to clog over time.


The extremely hot or freezing climate at different times can affect the battery state. Batteries should accommodate these changes effectively. Hence the constant operation of the cooling systems even when not in use.


Batteries can not escape getting older and weaker, and hence, heat is being lost at greater levels in those stages. For longevity, these future conditions should be pre-scheduled by building cooling systems to withstand the change.

Examples of Battery Thermal Management Systems


There are five basic processes that Nissan cools its battery down:

● The heat from the atmosphere is absorbed.

● It is compressed and turned to heat.

● Heated cold air then raises the temperature.

● The air is blown into the cabin.

● Decompressed heat turns into low temperature.

Chevrolet Volt

This vehicle cooling system works by:

Air moves to power inverter module to air separator to a 12v electric pump then to a plug-in charger assembly and an electronic cooling radiator.

Tesla Model 3

The coolant is routed through a series of parts by passing the radiator using heat from the electronics to heat the battery or air to cool.

Why Choose Winshare For Your EV Battery Cooling Solution Provider?

Batteries get more complex, and the heat is high. Thermal management gets more challenging also.

Winshare Thermal uses laser technology to create liquid cooling plates for batteries

 that will highly optimize the management of heat and its cooling.


Winshare has also serviced the best electronic vehicle systems for years, guaranteeing quality. With a base of more than a hundred engineers with quality experience from working on EV batteries for more than a decade, you have the best option you're looking for in Winshare.


To extend the battery life and maximize your electric vehicle performance, you should opt for a liquid cooling system as it performs the cooling operation best.


If you require a cooling system for your electric vehicle or replace an existing one, contact us now!

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