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.