Ai-assisted mist-cooled thermal management system for lithium-ion battery module with hydrophilic cell surfaces

Abstract

The present invention relates to an AI-assisted mist-cooling thermal management system (100) of cylindrical lithium-ion battery (LiB) module (200c) to enhance heat dissipation, maintain thermal-uniformity, enhance safety and cycle life. The system includes an acrylic air-flow channel (300) of divergent (401), straight (402) and convergent shape (403) to distribute atomized mist-air from intake fans (107) to cylindrical cells and discharge humid air by exhaust fans (108). Each cylindrical cell (101) is coated with hydrophilic material (202), to reduce the contact angle less than 20° which permits thin-film evaporation, electrical insulation, and resist corrosion. Dual atomizer arrays (109) on both sides of the cells form fine mist droplets of 10–30 µm supplied via a peristaltic pump. Dual intake fans (107) and exhaust fans (108) provide forced convection to accelerate evaporation and maintain uniform cell temperatures. An AI-based microcontroller processes real-time data from temperature and conductivity sensors to predicts and prevents faults and thermal runaway. So, by combining mist-cooling using thin film evaporation, hydrophilic surface treatment, air-flow management channel and intelligent control system results in a thermal management system which is effective in heat removal, minimized energy and water consumption, and increased battery life. It is portable, lightweight, scalable and can be applied to electric cars, hybrid cars, stationary storage, aerospace and industrial battery systems.