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Heat Pipe Integrated Cooling System of 4680 Lithium–Ion Battery for Electric Vehicles

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  • Yong-Jun Lee

    (School of Mechanical Engineering, College of Engineering, Chungbuk National University, 1 Chungdae-ro, Cheongju 28644, Chungbuk, Republic of Korea
    These authors contributed equally to this work.)

  • Tae-Gue Park

    (School of Mechanical Engineering, College of Engineering, Chungbuk National University, 1 Chungdae-ro, Cheongju 28644, Chungbuk, Republic of Korea
    These authors contributed equally to this work.)

  • Chan-Ho Park

    (School of Mechanical Engineering, College of Engineering, Chungbuk National University, 1 Chungdae-ro, Cheongju 28644, Chungbuk, Republic of Korea
    These authors contributed equally to this work.)

  • Su-Jong Kim

    (School of Mechanical Engineering, College of Engineering, Chungbuk National University, 1 Chungdae-ro, Cheongju 28644, Chungbuk, Republic of Korea
    These authors contributed equally to this work.)

  • Ji-Su Lee

    (School of Mechanical Engineering, College of Engineering, Chungbuk National University, 1 Chungdae-ro, Cheongju 28644, Chungbuk, Republic of Korea
    These authors contributed equally to this work.)

  • Seok-Ho Rhi

    (School of Mechanical Engineering, College of Engineering, Chungbuk National University, 1 Chungdae-ro, Cheongju 28644, Chungbuk, Republic of Korea
    These authors contributed equally to this work.)

Abstract

This study investigates a novel heat pipe integrated cooling system designed for thermal management of Tesla’s 4680 cylindrical lithium–ion batteries in electric vehicles (EVs). Through a comprehensive approach combining experimental analysis, 1-D AMESim simulations, and 3-D Computational Fluid Dynamics (CFD) modeling, the thermal performance of various wick structures and working fluid filling ratios was evaluated. The experimental setup utilized a triangular prism chamber housing three surrogate heater blocks to replicate the heat generation of 4680 cells under 1C, 2C, and 3C discharge rates. Results demonstrated that a blended fabric wick with a crown-shaped design (Wick 5) at a 30–40% filling ratio achieved the lowest maximum temperature ( T max of 47.0 °C), minimal surface temperature deviation (Δ T surface of 2.8 °C), and optimal thermal resistance ( R th of 0.27 °C/W) under 85 W heat input. CFD simulations validated experimental findings, confirming stable evaporation–condensation circulation at a 40% filling ratio, while identifying thermal limits at high heat loads (155 W). The proposed hybrid battery thermal management system (BTMS) offers significant potential for enhancing the performance and safety of high-energy density EV batteries. This research provides a foundation for optimizing thermal management in next-generation electric vehicles.

Suggested Citation

  • Yong-Jun Lee & Tae-Gue Park & Chan-Ho Park & Su-Jong Kim & Ji-Su Lee & Seok-Ho Rhi, 2025. "Heat Pipe Integrated Cooling System of 4680 Lithium–Ion Battery for Electric Vehicles," Energies, MDPI, vol. 18(15), pages 1-50, August.
    • Handle: RePEc:gam:jeners:v:18:y:2025:i:15:p:4132-:d:1717220
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    References listed on IDEAS

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    1. Jae-Hyun Ahn & Seok-Ho Rhi & Ji-Su Lee & Ki-Bum Kim, 2022. "Thermal Investigations of Hemispherical Shell Vapor Chamber Heat Sink," Energies, MDPI, vol. 15(3), pages 1-35, February.
    2. Eui-Hyeok Song & Kye-Bock Lee & Seok-Ho Rhi, 2021. "Thermal and Flow Simulation of Concentric Annular Heat Pipe with Symmetric or Asymmetric Condenser," Energies, MDPI, vol. 14(11), pages 1-23, June.
    3. Wang, Qian & Jiang, Bin & Li, Bo & Yan, Yuying, 2016. "A critical review of thermal management models and solutions of lithium-ion batteries for the development of pure electric vehicles," Renewable and Sustainable Energy Reviews, Elsevier, vol. 64(C), pages 106-128.
    4. Li, Shen & Marzook, Mohamed Waseem & Zhang, Cheng & Offer, Gregory J. & Marinescu, Monica, 2023. "How to enable large format 4680 cylindrical lithium-ion batteries," Applied Energy, Elsevier, vol. 349(C).
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