Optimization of 1D/3D Electro-Thermal Model for Liquid-Cooled Lithium-Ion Capacitor Module in High Power Applications

Lithium-ion capacitor technology (LiC) is well known for its higher power density compared to electric double-layer capacitors (EDLCs) and higher energy density compared to lithium-ion batteries (LiBs). However, the LiC technology is affected by a high heat generation problem in high-power applications when it is continuously being charged/discharged with high current rates. Such a problem is associated with safety and reliability issues that affect the lifetime of the cell. Therefore, for high-power applications, a robust thermal management system (TMS) is essential to control the temperature evolution of LiCs to ensure safe operation. In this regard, developing accurate electrical and thermal models is vital to design a proper TMS. This work presents a detailed 1D/3D electro-thermal model at module level employing MATLAB/SIMULINK® coupled to the COMSOL Multiphysics® software package. The effect of the inlet coolant flow rate, inlet coolant temperature, inlet and outlet positions, and the number of arcs are examined under the cycling profile of a continuous 150 A current rate without a rest period for 1400 s. The results prove that the optimal scenario for the LCTMS would be the inlet coolant flow rate of 500 mL/min, the inlet temperature of 30 °C, three inlets, three outlets, and three arcs in the coolant path. This scenario decreases the module’s maximum temperature (Tmax) and temperature difference by 11.5% and 79.1%, respectively. Moreover, the electro-thermal model shows ±5% and ±4% errors for the electrical and thermal models, respectively.

A Novel Air-Cooled Thermal Management Approach towards High-Power Lithium-Ion Capacitor Module for Electric Vehicles

This work presents an active thermal management system (TMS) for building a safer module of lithium-ion capacitor (LiC) technology, in which 10 LiCs are connected in series. The proposed TMS is a forced air-cooled TMS (ACTMS) that uses four axial DC 12 V fans: two fans are responsible for blowing the air from the environment into the container while two other fans suck the air from the container to the environment. An experimental investigation is conducted to study the thermal behavior of the module, and numerical simulations are carried out to be validated against the experiments. The main aim of the model development is the optimization of the proposed design. Therefore, the ACTMS has been optimized by investigating the impact of inlet air velocity, inlet and outlet positions, module rotation by 90° towards the airflow direction, gap spacing between neighboring cells, and uneven gap spacing between neighboring cells. The 3D thermal model is accurate, so the validation error between the simulation and experimental results is less than 1%. It is proven that the ACTMS is an excellent solution to keep the temperature of the LiC module in the desired range by air inlet velocity of 3 m/s when all the fans are blowing the air from both sides, the outlet is designed on top of the module, the module is rotated, and uneven gap space between neighboring cells is set to 2 mm for the first distance between the cells (d1) and 3 mm for the second distance (d2).

Investigation of Electrochemical Performance and Gas Swelling Behavior on Li4Ti5O12/Activated Carbon Lithium-Ion Capacitor with Acetonitrile-Based and Ester-Based Electrolytes

Lithium-ion capacitors (LICs) have gained significant attention due to the combination on the advantages of electric double-layer capacitors (EDLCs) and lithium-ion batteries (LIBs). Herein, the LIC pouch cell was fabricated by an activated carbon (AC) cathode and a Li4Ti5O12 (LTO) anode. Two organic electrolytes (1 mol L−1 LiBF4/acetonitrile (AN) and 1 mol L−1 LiPF6/ ethylene carbonate (EC) + ethyl methyl carbonate (EMC) + dimethyl carbonate (DMC)) were chosen and the gas swelling behavior was studied. Compared with the ester-based LIC, the AN-based LIC displays higher energy density of 13.31 Wh kg−1 at 11.4 W kg−1 and even provides a value of 9.1 Wh kg−1 at 1075 W kg−1. Because of the lower DC Resistance of 0.761 mΩ, the maximum power density of the AN-based LIC reaches 12.5 kW kg−1. The AN-based LIC delivers good stability with an energy retention of 88.3% after 900 cycles. It is discovered that the swelling behavior of AN-based LICs is more serious and the major component is H2. The difference of swelling behavior among the LICs, lithium nickel cobalt manganese oxide (NCM)/LTO LIB and AC/AC EDLC is proposed to be caused by the AC electrode and the interfacial reaction of LTO.

Holistic 1D Electro-Thermal Model Coupled to 3D Thermal Model for Hybrid Passive Cooling System Analysis in Electric Vehicles

Thermal management is the most vital element of electric vehicles (EV) to control the maximum temperature of module/pack for safety reasons. This paper presents a novel passive thermal management system (TMS) composed of a heat sink (HS) and phase change materials (PCM) for lithium-ion capacitor (LiC) technology under the premise that the cell is cycled with a continuous 150 A fast charge/discharge current rate. The experiments are validated against numerical analysis through a computational fluid dynamics (CFD) model. For this purpose, a comprehensive electro-thermal model based on an equivalent circuit model (ECM) is designed. The designed electro-thermal model combines the ECM model with the thermal model since the performance of the LiC cell highly depends on the temperature. Then, the robustness of the model is evaluated using a precise second-order ECM. The extracted parameters of the electro-thermal model are verified by the experimental results in which the voltage and temperature errors are less than ±5% and ±4%, respectively. Finally, the thermal performance of the HS-assisted PCM TMS is studied under the fast charge/discharge current rate. The 3D CFD results exhibit that the temperature of the LiC when using the PCM-HS as the cooling system was reduced by 38.3% (34.1 °C) compared to the natural convection case study (55.3 °C).