Thermal Management of Batteries Using a Variable-Conductance Insulation (VCI) Enclosure

This paper presents the design, analysis, and testing of an enclosure with variable conductance insulation (VCI) as a tool for thermal management of electric-vehicle batteries. VCI uses a hydride with an integral electric resistance heater to expel and retrieve a small amount of hydrogen gas into a vacuum space. By controlling the amount of hydrogen gas, the thermal conductance can be varied by more than 100:1, enabling the cooling loop (cold plate) to be mounted on the enclosure exterior. By not penetrating the battery enclosure, the cooling system is simpler and more reliable. Also, heat can be retained more effectively when desired. For high temperatures, radiation shields within the vacuum space are required. Ceramic spacers are used to maintain separation of the steel enclosure materials against atmospheric loading. Ceramic-to-ceramic thermal contact resistance within the spacer assembly minimizes thermal conductance.