Battery thermal management systems are integral to maximizing the performance and longevity of EV batteries, particularly in the context of significant advancements in battery technology. As innovations such as solid-state batteries and improvements in cathode chemistry reshape the landscape of EV batteries, thermal management becomes even more critical to ensure the efficient operation of these cutting-edge systems. Innovations in cathode chemistry, such as lithium nickel manganese cobalt oxide (NMC), lithium nickel cobalt aluminum oxide (NCA), and lithium iron phosphate (LFP), have led to higher energy densities and improved range in EV batteries. However, these advancements also bring challenges in terms of thermal management. For instance, the Tesla Model S uses LFP batteries. Tesla has developed a new battery design in which the cooling ribbons are now glued directly to the cooling ribbon, and the cooling ribbon spans a greater percentage of the cells' height. NMC batteries typically operate within a voltage range of 3.0'4.2 volts per cell. These have a nominal voltage of 3.6'3.7 volts per cell. NMC batteries use graphite anode and lithium compounds like Lithium Manganese Oxide (LiMn2O4) and Lithium Nickel Oxide (LiNiO2). Due to their current battery components, these batteries typically rely on air or liquid cooling.
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The design complexities in components used for a battery thermal management system involve a range of considerations to ensure optimal performance and safety. These complexities include selecting active, passive, or hybrid heat transfer solutions, such as forced air, liquid, or thermoelectric. Engineers must evaluate factors like heat dissipation, power consumption, flow rates, and thermal conductivity of coolants to regulate battery temperature effectively. Additionally, the design process involves modeling the detailed thermal behavior of the battery, selecting components, exploring different parameters, and optimizing the system's performance. Simulation tools like MATLAB and Simulink are utilized to analyze trade-offs, design controls, and assess the thermal impact of various design options. The system design also encompasses considerations like heat transfer paths, cooling plate connections, and thermal interface materials to represent the battery's thermal behavior accurately. Overall, the design of a battery thermal management system involves a comprehensive approach to ensure efficient operation and longevity of the battery under diverse operating conditions.
Modular design is a promising approach for developing next-generation battery thermal management systems (BTMS) that can improve performance, flexibility, and cost-effectiveness. There are some developments in this area, such as using mini-channel cooling plates with modular designs that can be easily integrated into battery packs. These plates allow for targeted cooling of individual battery cells or modules, improving temperature uniformity. The modular nature enables scalability to different pack sizes and configurations. Optimizing the structural layout of modular BTMS components can further improve performance. Studies have used topology optimization to design efficient liquid cooling plates. Incorporating modular vortex generators or perforated plates into air-cooled racks enhances airflow and heat transfer. Continued research in this area will further advance next-generation BTMS.
Battery thermal management systems (BTMS) face a tough challenge dealing with varied temperatures worldwide. In hot places like the Middle East or parts of Australia, batteries get even hotter, which can cause damage and reduce their lifespan. To fix this, BTMS needs robust cooling systems with larger radiators or multi-stage setups to keep temperatures consistent. Similarly, in cold climates such as Canada or Scandinavia, batteries don't work either, leading to less range and efficiency. To solve this, BTMS uses heating elements and waste heat to keep batteries working correctly. Finding the right balance between cooling and heating is challenging. BTMS must work well in climates, irrespective of the region, to keep batteries functioning smoothly
The research study involved extensive secondary sources, such as company annual reports/presentations, industry association publications, magazine articles, directories, technical handbooks, World Economic Outlook, trade websites, technical articles, and databases, to identify and collect information on the battery thermal management system market. Primary sources, such as experts from related industries, automobile OEMs, and suppliers, were interviewed to obtain and verify critical information and assess the growth prospects and market estimations.
Secondary sources for this research study include corporate filings, such as annual reports, investor presentations, and financial statements; trade, business, and professional associations; whitepapers, marklines, and the OICA (International Organization of Motor Vehicle Manufacturers); certified publications; articles by recognized authors; directories; and databases. Secondary data was collected and analyzed to determine the overall market size, further validated by primary research.
Extensive primary research was conducted after understanding the BTMS market scenario through secondary research. Several primary interviews were conducted with market experts from the demand side (vehicle manufacturers, country-level government associations, and trade associations) and the supply side (BTMS manufacturers, component providers, and system integrators). The regions considered for the research include North America, Europe, the Asia Pacific, and the Rest of the World. Approximately 17% and 83% of primary interviews were conducted from the demand and supply sides. Primary data was collected through questionnaires, emails, and telephonic interviews. In the canvassing of primaries, various departments within organizations, such as sales, operations, and marketing, were covered to provide a holistic viewpoint in this report.
After interacting with industry experts, brief sessions were conducted with highly experienced independent consultants to reinforce the findings from the primaries. This, along with the in-house subject matter experts' opinions, led to the findings described in this report.
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A detailed market estimation approach was followed to estimate and validate the volume and value of the BTMS market and other submarkets, as mentioned below.
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After arriving at the overall market size through the aforementioned methodology, the BTMS market was split into several segments and subsegments. The data triangulation procedure was employed, wherever applicable, to complete the overall market engineering process and arrive at the exact market value for key segments and subsegments. The extrapolated market data was triangulated by studying various macro indicators and regional trends from both the demand- and supply-side participants.
BTMS Market: According to Grayson Thermal Systems, BTMS encompasses technologies and solutions that help regulate and control the temperature of batteries in electric vehicles, specifically battery electric (BEV), plug-in hybrid electric vehicles (PHEVs), and fuel cell electric (FCEV) vehicles. These systems help maintain optimal battery performance, range, and service life by ensuring that batteries operate within a specified temperature range. BTMS includes various components such as cooling systems, heating systems, insulation materials, sensors, and control algorithms to efficiently manage battery temperatures under different operating conditions.
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The electric vehicle battery thermal management system market is segmented into Type, Technology, Propulsion Type and Vehicle Type.
Battery thermal management system (BTMS) is used to maintain a battery pack of electric vehicles at an optimum average temperature during the electrochemical processes occurring in cells. High battery temperatures can reduce performance, shorten battery life, and pose a risk of explosion. Therefore, battery thermal management system is essential for all battery modules. The main purpose of battery thermal management system is regulation of temperature of the battery cell to extend the life of the battery. The battery thermal management system is expected to allow the pack to work under a good range of climatic conditions and supply ventilation. Furthermore, in electric vehicles, thermal management makes it possible to not only improve battery power and longevity, but also to reduce the size of electric engines. Thus, temperature is the main parameter that needs to be controlled in a battery. Hence, it is necessary to employ battery thermal management system in electric vehicles.
Factor such as growing demand for electric vehicles, long range & fast charging technology, and favorable emission standards propel the electric vehicle battery thermal management system market growth. However, design challenges and complexities in components used for battery thermal management system and lack of sufficient infrastructure for electric vehicles are factors that hinder the growth of the EV BTMS market. Increase in technological changes in lithium-ion batteries and innovation in battery cooling system provide growth opportunities for the electric vehicle battery thermal management system market.
The electric vehicle battery thermal management system market is segmented on the basis of type, technology, propulsion type, vehicle type and region. By type, it is divided into active, passive, and hybrid. By technology, it is segmented into liquid cooling and heating, air cooling and heating, and others. On the basis of propulsion type, it is divided into battery-electric vehicles (BEV), hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEVs), and fuel cell electric vehicles. By vehicle type, the market is bifurcated into passenger vehicles, commercial vehicles, and two-wheelers and three-wheelers. On the basis of region, it is divided into North America, Europe, Asia-Pacific, and LAMEA.
The key players operating in this electric vehicle battery thermal management system market are Modine Manufacturing Company, Continental AG, Gentherm, Dana Limited, Hanon Systems, Valeo, MAHLE GmbH, Robert Bosch GmbH, Grayson, and VOSS Automotive GmbH.
Surge in Demand for Electric Vehicles
The electric vehicle market is growing exponentially due to factors such as climate change and efforts to achieve net zero emissions. Moreover, favorable incentives and policies introduced by governments of different countries to promote electric vehicles boost the growth of the EV industry. For instance, in , in California, the Clean Vehicle Rebate Project (CVRP) promoted clean vehicle adoption in California by offering rebates ranging from $1,000 to $7,000 for purchases or leases of new zero-emission vehicle. Also, in , New Zealand proposed Clean Car Discount, in which new car buyers receive $8,625 rebate for electric vehicles (EVs) less than $80,000, including GST and road costs. Rise in awareness of climate change and surge in demand for electric cars leads to an increase in the production of electric vehicles. For instance, according to a report by the IEA organization, , EV vehicles globally reached 6.7 million units in , a 3.7 million units over , accounting for 4.1% of the market share. In , the electrical percentage of automobile income was about 2.4%, increasing from about 2% in . Thermal management system is required to protect and insulate the battery of electric vehicles to ensure the safety and efficient performance of the battery cell. With the increasing popularity of battery-powered vehicles, manufacturers have begun to develop improved battery heat management systems. Thus, expansion of electric vehicle market promotes the growth of the battery thermal management system market. Moreover, some countries announced policies banning and phasing out gasoline and diesel cars. Such measures taken by various governments also encourage automakers and other market players to adopt the new electric vehicle trend. For instance, in , Ford Motor plans to invest $20 billion in an effort to expand electrification of its lineup with an investment of $20 billion. Also, in , China's tech giant, Xiaomi officially confirmed its plans to enter the smart electric vehicle business by investing RMB 10 billion (roughly $1.55 billion) in the first phase. Efficient battery thermal management system (BTMS) is one of the most important technologies for the success of electric vehicles. Therefore, increase in demand for electric vehicles boosts the demand for electric vehicle battery thermal management system.
Increase in long range and fast charging technology in electric vehicles
As EVs grow in popularity, new car buyers are skeptical about sufficient range provided by electric vehicles for normal driving needs. This range anxiety has encouraged automobile manufacturers to produce EV with longer range. Increasing the size of the battery pack is the simplest way to improve EV range. For instance, on April 20, , Tata Motors launched a long-range Nexon EV with a larger 40kWh battery pack and a range of 400km. Electric vehicles equipped with a larger battery pack generate enormous amounts of heat; hence battery heat management becomes necessary to maintain adequate temperature range for effective functioning of vehicle. The battery temperature has a strong effect on the charging and discharging rate of the battery, which further affects the range of the vehicle, which develops the need for suitable battery heat management system. According to a report published by International Energy Agency (IEA) in , the average driving range of electric vehicles has been steadily growing. The weighted average range of the new battery-powered electric vehicle in was about 350km (km), an increase from 200km in . Thus, the increasing production of long range vehicles is expected to require a dedicated battery thermal management system to enhance safety and efficiency of electric vehicles, which promotes the growth of the battery thermal management system market. Moreover, fast-charging technology is rapidly expanding and evolving as it allows vehicles to be charged within a short period of time. For instance, in January , Voltempo, a leading developer of new electric vehicle (EV) technologies, introduced Hyper Charging, the world's fastest charging system. Also, companies such as Tesla and EVgo are already building fast-charging infrastructure across North America. For instance, in February , EVgo, the U.S.'s largest public fast charging network for electric vehicles (EVs) expanded its fast charging network for Tesla drivers to charge at more EVgo stations across the country. Moreover, in April , Hyundai a South Korean global automotive manufacturing company, announced a collaboration with retail giant, Lotte Group and KB Asset Management to expand Korea's ultra-fast charging infrastructure. In addition, governments of different countries have taken initiatives to promote the deployment of fast charging stations. For instance, in , the government of India decided to change the guidelines for charging stations for electric vehicles to give developers the freedom to choose the charging infrastructure technology. Government decided to install both CHAdeMO and Combined Charging System (CCS) fast charging technologies, in addition to the existing Bharat standard at public electric vehicle charging stations. The uniformity of the temperature distribution of the battery module affects the inconsistency between the battery cells, resulting in non-uniform aging rate and shortened battery module life. The fast charging technology is responsible for large heat generation and degradation of the battery as lithium-ion batteries generate enormous heat at high current charge rates. Thus, a battery thermal management system is required to extract heat efficiently and maintain uniform temperature distribution in the battery pack. Therefore, the growing trend of long range and fast charging technology propel growth of the electric vehicle battery thermal management system market.
Design challenges and complexities in components used for battery thermal management system
The design of battery thermal management system is complex. Increasing power requirements without compromising system performance and reliability is a major issue in thermal component design. Pipe connections are at risk of leaks as the battery gets older in liquid cooling battery thermal management system. The connections, battery modules pump, and valves of the system must all remain intact. Corrosion can occur in liquid cooling systems where cold plates can corrode as the liquid glycol ages. Therefore, the coolant is expected to be replaced as part of vehicle maintenance. Maintenance battery thermal management system (BTMS) is difficult due to high repair costs and bulky and cumbersome cables. Such complicated configuration and maintenance hinder the growth of the EV battery thermal management system market. There are also challenges posed during manufacturing of the thermal components of battery thermal management system, which comprises of selection of coolant, design of optimal flow channels, and complexity of the model and flow. Innovative yet fully functional battery thermal management system design requires rigorous monitoring, quality testing, and continuous improvement of the entire process. Also, all current quality and safety (Q & S) standards need to be taken into account during the design of battery thermal management system. Rapid temperature rises due to high power can be dangerous as they can cause internal short circuits, physical damage, fires or explosions, which is also called thermal runway. Thus, the system must be designed to withstand wide temperature ranges at all times. For instance, in August , Tesla car ignited overnight while charging, igniting another Tesla (second Model S) next door, causing a major house fire. Battery of the electric vehicles is required to function properly in hot and humid conditions that prevail across India. Also, the effects of cold weather dramatically reduce battery life and increase internal impedance. The cold climate reduces range of electric vehicles by slowing down the chemical reaction in battery cells. Therefore, such design challenges and complexities associated with components of the battery thermal management system hinder the growth of the EV BTMS market.
Increase in technological innovations in lithium-ion batteries
Due to the high energy per unit of mass of lithium-ion batteries corresponding to other electrical energy storage systems, lithium-ion batteries are extensively used in electric vehicles. It offers high energy efficiency, high power-to-weight ratio, good high-temperature performance, and low self-discharge. The growing trend of electric vehicles puts high demands on the performance of a battery. A vast amount of public and private investment in lithium-ion batteries for technological innovations for better performance drives the growth of electric vehicles, hence, providing growth opportunities for the electric vehicles battery thermal management system market. For instance, in , Ford Motor Co and BMW AG announced a $130 million funding round for Solid Power, an all-solid-state battery startup to develop solid state batteries for electric vehicles to store more energy and provide safety and charge faster. Moreover, in June , researchers at the University of Waterloo, Canada and members of the Joint Center for Energy Storage Research (JCESR) U.S. have discovered a new solid electrolyte for solid-state lithium-ion batteries, which is expected to enhance safety, reduce the size of batteries, increase efficiency and offer fast charging. The ideal operating temperature range for automotive batteries is 20-45 ° C. Temperature higher or lower than the optimum temperature can lead to deformation of the batteries which causes spark a fire or explosion. For instance, in , Hyundai Kona Electric exploded in its owner's garage in Montreal, Canada. Heat dissipation is significant in electric vehicles to prevent damage to the battery pack from the heat generated during charging and discharging of battery. Owing to this, innovations in lithium ion batteries are carried out by replacing the flammable liquid electrolyte in commonly used Lithium ion batteries with an inorganic solid-state electrolyte to provide more safety and mitigate explosion accidents. These advancements in technologies of lithium ion battery support EV efficiency and charging capabilities that require an efficient and compact battery thermal management system (BTMS) which bolster the growth of the electric vehicle battery thermal management system.
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