Battery packages development in cooling and packaging solutions (voltage levels)
Hasan, S M Rashed (2025)
Diplomityö
2025
School of Energy Systems, Sähkötekniikka
Kaikki oikeudet pidätetään.
Julkaisun pysyvä osoite on
https://urn.fi/URN:NBN:fi-fe2025061668718
https://urn.fi/URN:NBN:fi-fe2025061668718
Tiivistelmä
As electric vehicles (EVs) evolve towards higher performance, extended range, and faster charging capabilities, the battery pack has become a critical determinant of system efficiency, thermal safety, and structural design. One of the most influential yet complex variables in battery system architecture is voltage level. This thesis investigates how varying voltage platforms—ranging from low-voltage (48 V) to high-voltage (800 V+)—affect the thermal behaviour, packaging strategies, and cooling requirements of lithium-ion battery systems used in electric mobility.
The study begins with a literature-based exploration of voltage-dependent energy and thermal dynamics, establishing how voltage influences power electronics, thermal load, and insulation demands. It then compares thermal management solutions—passive air cooling, active liquid cooling, phase-change materials (PCM), and refrigerant-based integrated thermal systems (ITMS)—across different voltage classes, highlighting their effectiveness and limitations. Particular attention is given to how higher voltages increase heat density, necessitating more advanced and space-efficient thermal control systems.
In parallel, the thesis explores how voltage levels impact packaging complexity. As voltage increases, packaging must balance electrical insulation, thermal conductivity, mechanical robustness, and compliance with safety standards. Using simulation-based analysis and real-world component data, the study evaluates packaging materials and structural configurations for different voltage tiers, with a focus on design trade-offs and crashworthiness.
Ultimately, this research presents a voltage-centric framework for battery pack design that integrates thermal, electrical, and structural considerations. The findings provide engineering insights for selecting scalable cooling solutions and packaging strategies tailored to voltage-specific EV platforms. The thesis concludes by discussing future trends—such as modular architectures, direct refrigerant cooling, and recyclable pack materials—pointing towards more efficient and sustainable high-voltage battery systems.
The study begins with a literature-based exploration of voltage-dependent energy and thermal dynamics, establishing how voltage influences power electronics, thermal load, and insulation demands. It then compares thermal management solutions—passive air cooling, active liquid cooling, phase-change materials (PCM), and refrigerant-based integrated thermal systems (ITMS)—across different voltage classes, highlighting their effectiveness and limitations. Particular attention is given to how higher voltages increase heat density, necessitating more advanced and space-efficient thermal control systems.
In parallel, the thesis explores how voltage levels impact packaging complexity. As voltage increases, packaging must balance electrical insulation, thermal conductivity, mechanical robustness, and compliance with safety standards. Using simulation-based analysis and real-world component data, the study evaluates packaging materials and structural configurations for different voltage tiers, with a focus on design trade-offs and crashworthiness.
Ultimately, this research presents a voltage-centric framework for battery pack design that integrates thermal, electrical, and structural considerations. The findings provide engineering insights for selecting scalable cooling solutions and packaging strategies tailored to voltage-specific EV platforms. The thesis concludes by discussing future trends—such as modular architectures, direct refrigerant cooling, and recyclable pack materials—pointing towards more efficient and sustainable high-voltage battery systems.