Review of Production Electric Vehicle Battery Thermal Management Systems and Experimental Testing of a Production Battery Module

This paper reviews battery cooling systems in production fast-charging electric vehicles and the characteristics of different cooling channel pathways discussed in literature. In production fast charging electric vehicles, the predominant cooling method was found to be liquid edge cooling, where battery modules sit on top of a cooling manifold which cools one edge of each cell. Based on this, four main classes of cooling channel pathways are identified with examples of real-life implementation. A battery module from a Porsche Taycan electric vehicle is also instrumented with temperature sensors to observe the thermal characteristics across the cell surface during fast charging, and the results are presented. With fast charging, the Taycan module charged from 0 to 80% SOC within 24.27 minutes. The maximum temperature rise of the battery cells during the fast charge was 28.14°C and the temperature deviation across the cell surface was ±2.06°C.