Open Access

ARTICLE

Innovative Dual Two-Phase Cooling System for Thermal Management of Electric Vehicle Batteries Using Dielectric Fluids and Pulsating Heat Pipes

Federico Sacchelli¹, Luca Cattani^1,2, Matteo Malavasi¹, Fabio Bozzoli^1,2,*, Corrado Sciancalepore¹

1 Department of Engineering for Industrial Systems and Technologies, University of Parma, Parco Area delle Scienze 181/A, Parma, 43124, Italy
2 SITEIA.PARMA Interdepartmental Centre, University of Parma, Parco Area delle Scienze, Parma, 43124, Italy

* Corresponding Author: Fabio Bozzoli. Email:

(This article belongs to the Special Issue: Heat and Mass Transfer Applications in Engineering and Biomedical Systems: New Developments)

Frontiers in Heat and Mass Transfer 2025, 23(5), 1351-1364. https://doi.org/10.32604/fhmt.2025.064154

Received 06 February 2025; Accepted 25 July 2025; Issue published 31 October 2025

Abstract

This study investigates the feasibility of a novel dual two-phase cooling system for thermal management in lithium-ion batteries used in electric vehicles (EVs). The proposed system aims to combine low-boiling dielectric fluid immersion cooling and pulsating heat pipes (PHPs), in order to leverage the advantages of both technologies for efficient heat dissipation in a completely passive configuration. Experimental evaluations conducted under different discharge conditions demonstrate that the system effectively maintains battery temperatures within the optimal range of 20–40°C, with enhanced temperature uniformity and stability. While the PHP exhibited minimal impact at low power, its role became critical under higher discharge rates, ensuring efficient vapor condensation and pressure stability. The results highlight the potential of this passive cooling system to improve battery performance and safety, supporting its application in EV battery thermal management. Future work aims to optimize design parameters and evaluate real battery modules under ultra-fast charging scenarios.

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