All Case StudiesEnergy Storage
Battery Pack Thermal System
Power
200kWh
Result
45% cooling improvement
Industry
Energy Storage
OF
The Challenge
A battery systems company was developing a 200kWh commercial vehicle battery pack with aggressive fast-charging requirements (2C rate). Their existing thermal design couldn't maintain cell temperature uniformity, leading to capacity fade and safety concerns. The pack needed to support 4,000+ charge cycles while maintaining less than 3°C temperature variation across all cells during fast charging.
Our Approach
- Mapped thermal behavior of individual cells under various charge/discharge profiles
- Designed direct liquid cooling system with parallel flow distribution
- Optimized cooling plate geometry for uniform heat extraction
- Implemented cell-level temperature monitoring with thermal runaway detection
- Selected low-viscosity dielectric coolant for improved heat transfer
- Validated thermal uniformity through accelerated cycling tests
Results
45%
Cooling Improvement
Heat extraction rate increased
<2°C
ΔT Uniformity
Cell-to-cell variation minimized
4,500+
Cycle Life
Exceeded target cycle count