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This thesis consists of three main objectives: fundamental and literature review of EV batteries, experimental development, and validation of two liquid cooling battery modules, thermal modeling and comparison of the inter-cell cooling battery module. / The traditional vehicles with internal combustion engine have resulted in severe environmental pollution, which motivates the development of electric vehicles and hybrid electric vehicles. Due to a low energy density and long refueling time of the battery pack, it is still hard for electric vehicles and hybrid electric vehicles to be widely accepted by the consumers. As the batteries with a better ultra-fast charging capability are massively produced, the range anxiety issue is somewhat alleviated. During a charging with large current magnitude, the battery generally has a great amount of heat generation and evident temperature rise. Therefore, a thermal management system is necessary to effectively dissipate the battery loss and minimize the degradation mechanisms caused by extreme temperature. The motivation of this thesis is to study the discipline of the battery thermal management system as an application for electric vehicles. The design methodologies are presented in both experiment test and numerical simulation. For the comparative study between active liquid cooling methods for a lithium-ion battery module using experimental techniques, two battery modules with three Kokam Nickel Manganese Cobalt battery cells connected in parallel are developed. One has liquid coolant flowing along the edge of the model, and another with liquid coolant flowing between the cells. Several characterization tests, including thermal resistance tests, fast charging tests up to 5C, and drive cycle tests are designed and performed on the battery module. The inter-cell cooling module has a lower peak temperature rise and faster thermal response compared to the edge cooling module, i.e., 4.1⁰C peak temperature rise under 5C charging for inter-cell cooling method and 14.2⁰C for edge cooling method. The thermal models built in ANSYS represent the numerical simulation of the inter-cell cooling module as a comparison with the experiment. A cell loss model is developed to calculate the battery heat generation rate under ultra-fast charging tests and a road trip test, which are further adopted as the inputs to the thermal models. The simulation of the 5C ultra-fast charging test gives the peak temperature rise just 0.47⁰C lower than the experimental measurement, it indicates that the FEA thermal models can provide an accurate temperature prediction of the battery module. / Thesis / Master of Applied Science (MASc) / With a demanding market of electric vehicles, battery technologies have grown rapidly in recent years. Among all the battery research topics, the development of ultra-fast charging, that can fully charge the battery pack within 15 minutes, is the most promising direction to address the range anxiety and improve the social acceptance of electric vehicles. Nevertheless, the application of ultra-fast charging has many challenges. In particular, an efficient thermal management system is significant to guarantee the safety and prolong the service life of the battery pack. This thesis contributes to study the fundamentals of the battery field, and design liquid cooling systems to observe the thermal behavior of a battery prototype module under fast charging and general use. FEA thermal modeling of the battery module is developed to provide a guide for further test validation.

In order to support UCLA’s development of the 3 cm Miniature Xenon Ion (MiXI) thruster, Cal Poly has a 3 cm thruster under development. This version, called MiXI Cal Poly Version 1 (MiXI-CPv1), is complete and has been utilized in vacuum chamber thermal validation testing. Testing on this version was used to check the validity of heat transfer simulations modeled in SolidWorks. Investigations of the 3 cm ion thruster configuration were intended to discover the driving factors affecting the thermal behavior of the discharge chamber and surrounding design space. Numerical simulations indicate that the heating of the samarium cobalt permanent magnets can be mitigated through the implementation of two proposed modifications. The first modification is to implement a 2% thoriated tungsten filament cathode. This design exhibited maximum permanent magnet temperatures of 325°C, twenty-five degrees below the maximum upper temperature of 350°C. Since some magnetic degaussing effects have been observed at temperatures above 300°C, the aforementioned solution can be combined with a thruster design modification to achieve a reduced permanent magnet temperature of 298°C. This modification would involve increase the anode wall thickness from approximately 0.7 mm to 2 mm below the permanent magnet ring, creating a stepped anode design. Additionally, less effective solutions were proposed and modeled and are presented for completeness.

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With the increase dependency on electricity to provide correct form of electricity for lightning, machines, and home and office appliances, the need for the introduction of high reliability power electronics in converting the raw form of electricity into efficient electricity for these applications is uprising. One of the most common failures in power electronics is temperature related failure such as overheating. To address the issue of overheating, thermal management becomes an important mission in the design of the power electronics to ensure the functional power electronics. Different approaches are taken by academia and industry researchers to provide efficient power electronics. In particular, the Center for Power Electronics System (CPES) at Virginia Tech and four other universities presented the IPEM approach by introducing integrated power electronics modules (IPEM) as standardized units that will enable greater integration within power electronics systems and their end-use application. The IPEM approach increases the integration in the components that make up a power electronics system through novel a packaging technique known as Embedded Power technology. While the thermal behavior of commonly used packages such as pin grid arrays (PGA), ball grid array (BGA), or quad flat pack (QFP) are well-studied, the influence of the Embedded Power packaging architecture on the overall thermal performance of the IPEMs is not well known. This motivates the presentation of this dissertation in developing an in-depth understanding on the thermal behavior of the Embedded Power modules. In addition, this dissertation outlines some general guidelines for the thermal modeling and thermal testing for the Embedded Power modules. Finally, this dissertation summarizes a few thermal design guidelines for the Embedded Power modules. Hence, this dissertation aims to present significant and generalized scientific findings for the Embedded Power packaging from the thermal perspective. Both numerical and experimental approaches were used in the studies. Three-dimensional mathematical modeling and computational fluid dynamics (CFD) thermal analyses were performed using commercial numerical software, I-DEAS. Experiments were conducted to validate the numerical models, characterize the thermal performance of the Embedded Power modules, and investigate various cooling strategies for the Embedded Power modules. Validated thermal models were used for various thermal analyses including identifying potential thermal problems, recognizing critical thermal design parameters, and exploring different integrated cooling strategies. This research quantifies various thermal design parameters such as the geometrical effect and the material properties on the thermal performance of the Embedded Power modules. These parameters include the chip-to-chip distance, the copper trace area, the polyimide thickness, and the ceramic materials. Since the Embedded Power technology utilizes metallization bonding as interconnection, specific design parameters such as the interconnect via holes pattern and size, the metallization thickness, as well as the metallization materials were also explored to achieve best results based on thermal and stress analyses. With identified potential thermal problems and critical thermal design parameters, different integrated cooling strategies were studied. The concept of integrated cooling is to incorporate the cooling mechanisms into the structure of Embedded Power modules. The results showed that simple structural modifications to the current Embedded Power modules can reduce the maximum temperature of the module by as much as 24%. Further improvement can be achieved by employing double-sided cooling to the Embedded Power modules. Based on the findings from the thermal analyses, general design guidelines were developed for future design of such Embedded Power modules. In addition, thermal modeling and testing guidelines for the Embedded Power modules were also outlined in this dissertation. / Ph. D.

Continental rifting ultimately creates a deep accommodation space for sediment. When a major river flows into a late-stage rift, thick deltaic sediment can change the thermal regime and alter the mechanisms of extension and continental breakup. The Salton Trough, the northernmost rift segment of the Gulf of California plate boundary, has experienced the same extension as the rest of the Gulf, but is filled to sea level by sediment from the Colorado River. Unlike the southern Gulf, seafloor spreading has not initiated. Instead, seismicity, high heat flow, and minor volcanoes attest to ongoing rifting of thin, transitional crust. Recently acquired controlled-source seismic refraction and wide-angle reflection data in the Salton Trough provide constraints upon crustal architecture and active rift processes. The crust in the central Salton Trough is only 17-18 km thick, with a strongly layered but relatively one-dimensional structure for ~100 km in the direction of plate motion. The upper crust includes 2-3 km of Colorado River sediment. The basement below the sediment is interpreted to be similar sediment metamorphosed by the high heat flow and geothermal activity. Meta-sedimentary rock extends to at least 7-8 km depth. A 4-5 km thick layer in the middle crust is either additional meta-sedimentary rock or stretched pre-existing continental crust. The lowermost 4-5 km of the crust is rift-related mafic magmatic material underplated from partial melting in the hot upper mantle. North American lithosphere in the Salton Trough has been almost or completely rifted apart. The gap has been filled by ~100 km of new transitional crust created by magmatism from below and sedimentation from above. These processes create strong lithologic, thermal, and rheologic layering. Brittle extension occurs within new meta-sedimentary rock. The lower crust, in comparison, stretches by ductile flow and magmatism is not localized. This seismic interpretation is also supported by 1D thermal and rheological modeling. In this passive rift driven by far-field extensional stresses, rapid sedimentation keeps the crust thick and ductile, which delays final breakup of the crust and the initiation of seafloor spreading. / Ph. D.

Major challenges in maintaining quality and reliability in today’s microelectronics devices come from the ever increasing level of integration in the device fabrication, as well as the high level of current densities that are carried through the microchip during operation. In order to have a framework for design and reliability assessment, it is imperative to develop a predictive capability for the thermal response of micro-electronic components. A computationally efficient and accurate multi-scale transient thermal methodology was developed using a combination of two different approaches: “Progressive Zoom-in” method and “Proper Orthogonal Decomposition (POD)” technique. The proposed technique has the capability of handling several decades of length scale from tens of millimeter at “package” level to several nanometers at “interconnects” level at a considerably lower computational cost, while maintaining satisfactory accuracy. This ability also applies for time scales from seconds to microseconds corresponding to various transient thermal events. The proposed method also provides the ability to rapidly predict thermal responses under different power input patterns, based on only a few representative detailed simulations, without compromising the desired spatial and temporal resolutions. It is demonstrated that utilizing the proposed model, the computational time is reduced by at least two orders of magnitude at every step of modeling. Additionally, a novel experimental platform was developed to evaluate rapid transient Joule heating in embedded nanoscale metallic films representing buried on-chip interconnects that are not directly accessible. Utilizing the state-of-the-art sub-micron embedded resistance thermometry the effect of rapid transient power input profiles with different amplitudes and frequencies were studied. It is also demonstrated that a spatial resolution of 6 µm and thermal time constant of below 1 µs can be achieved using this technique. Ultimately, the size effects on the thermal and material properties of embedded metallic films were studied. A state-of-the-art technique to extract thermal conductivity of embedded nanoscale interconnects was developed. The proposed structure is the first device that has enabled the conductivity measurement of embedded metallic films on a substrate. It accounts for the effect of the substrate and interface without compromising the sensitivity of the device to the thermal conductivity of the metallic film. Another advantage of the proposed technique is that it can be integrated within the structure and be used for measurements of embedded or buried structures such as nanoscale on chip interconnects, without requiring extensive micro-fabrication. The dependence of the thermal conductivity on temperature was also investigated. The experimentally measured values for thermal conductivity and its dependence on temperature agree well with previous studies on free-standing nanoscale metallic bridges.

Les travaux présentés dans cette thèse concernent la modélisation, le dimensionnement et la commande d'un coffre composé de supercondensateurs et d'un convertisseur DC/DC permettant d’alimenter les auxiliaires d’un trolleybus ou les moteurs de traction lors des coupures de la ligne aérienne. Dans la première partie, nous nous sommes intéressés au dimensionnement du système destockage pour une application du type récupération de l'énergie au freinage d'un trolleybus. Les modèles directes et inverses de la chaine cinématique ont été étudiés afin de définir une stratégie de dimensionnement du coffre s'appuyant sur le plan de Ragon. La seconde partie aborde la problématique de la fiabilité de l'élément de stockage. Le but est d'évaluer les contraintes que subissent les supercondensateurs en cours de fonctionnement et de prédire le vieillissement de ces derniers. Pour ce faire, nous avons développé et validé un modèle électrothermique du coffre de supercondensateurs. Ce modèle électrothermique a également été couplé à des lois de vieillissement permettant ainsi de prendre en compte les variations paramétriques majeures de ce système. Les résultats de ce couplage montrent l'impact de la dispersion des températures à l'intérieur du coffre sur la durée de vie de chaquesupercondensateur et du système de stockage. Finalement, le contrôle du convertisseur statique (hacheur Buck/Boost) associé auxsupercondensateurs est abordé. Une étude théorique a été menée pour synthétiser des lois de commande par mode de glissement et par PI appliqués au mode élévateur du hacheur (Boost). Ces lois de commande ont été validées sur un banc de test constitué d'un hacheur réversible, d'une alimentation DC, d'une charge résistive et de huit supercondensateurs. La comparaisondes résultats expérimentaux mettre en évidence l'intérêt de la commande par mode glissant enraison de sa robustesse et de sa réactivité par rapport à une commande classique (PI). / The studies presented in this thesis concern the thermal modeling, sizing and control of a stack composed of supercapacitors and DC/DC converter that feeds the auxiliaries or traction motors of the trolleybus in the case of electrical microcuts. In the first part, we were interested in the sizing of the storage system for an application concerning the recovering braking energy of a trolleybus. Direct and inverse models of the kinematic chain were studied in order to define a design strategy based on the Ragon. The second part concerns the reliability of the storage system. The aim is to evaluate the stresses on supercapacitors during cycling and to predict the aging of the components. Toachieve this goal, we have developed and validated an electrothermal model of the stack. This model was then coupled to aging laws allowing taking into account the major parametric variation of the system. The results show the impact of the dispersion of temperatures inside the stack on the life time of each supercapacitors in the storage system. Finally, the control of the static converter (Buck/Boost converter) combined with supercapacitors is analyzed. A theoretical study was conducted to synthesize PI and sliding mode controller applied to a boost converter. This control laws has been validated on a test bench consisting of a reversible converter, a DC power supply, a resistive load and eight supercapacitors. The experimental results show the advantage of sliding mode control in terms of robustness and reactivity compared to a classical PI control.

Shape Memory Alloy is an amazing material, which can “remember” and return to its original shape when heated due to its temperature dependent phase transformation. Shape Memory Alloy wire has significant potential for application in the automobile industry due to its high ratio of energy / weight and silent actuation. However, a dependable method to measure the operating temperature of SMA wire and a reliable heat transfer model to characterize the dynamics of the SMA wire limit its widespread use in the automobile industry. This thesis presents a detailed description of the work performed to develop a reliable method for determining surface temperature of current carrying SMA wires and the development of a heat transfer correlation for natural convection cooling of heated SMA wires. The major findings of the research are as follows: When a spot welded thermocouple measures the temperature of a current carrying SMA wire, there is a “spurious voltage” ΔV added to the thermo electro-motive force (EMF) of the thermocouple as a result of a voltage drop across the two points of contact that the thermocouple wires make with the SMA wire. This leads to an erroneous temperature reading that can be higher or lower than the actual temperature depending on the direction of current flow. When the carrying current is reversed in direction, the “spurious voltage” becomes –ΔV allowing a correct temperature reading to be obtained by averaging the readings based on opposed current flow. A two-step spot welding procedure for attaching thermocouples to SMA wire can eliminate the influence of the “spurious voltage” in the temperature reading. By spot welding the thermocouple wires onto the SMA wire one by one, the thermocouple lead offset is eliminated and the thermocouple provides an accurate point source reading. Infrared thermal imaging can be a good supplement in the experiment to monitor errors in temperature readings from thermocouples. Due to the curvature of the SMA wire, the temperatures of the locations on the SMA wire that are the closest to the infrared camera represent the temperature of the SMA wire. So a line analysis across the SMA wire on the software “ThermaCAM” is required to determine the temperature of the SMA wire by infrared thermal imaging and the highest temperature on the line is the temperature of the SMA wire. A new natural convective heat transfer correlation comprising the inclination angle φ is developed based on experimental results, which can be used to predict the temperature of a SMA wire given its diameter and inclination angle. The comparisons show that the new correlation agrees with existing correlations in a vertical orientation and for small Rayleigh numbers (0.001 < RaD < 0.05) in the horizontal orientation. The correlation developed in this work for horizontal orientation tends to overestimate values of Nusselt numbers as predicted in other correlations when the Rayleigh number is high (0.05 < RaD < 0.6). It is speculated that this overestimation can be attributed to a temperature distortion associated with thermocouple measurement at or near ambient pressure conditions.

Thermo-mechanical failure of components in planar-type solid oxide fuel cells (SOFCs) is a major obstacle on the path to bringing this technology to commercial viability. The probability of material degradation and failure in SOFCs depends strongly on the local temperature gradients at the interfaces of different materials. Therefore, it is of paramount importance to accurately predict and manage the temperature fields within the stack, especially near the interfaces. In this work we consider three effects in detail. First, we analyze radiative heat transfer effects within the semi-transparent solid electrolyte and compared them to thermal conduction. We also, present the modeling approach for calculation of surface-to-surface exchange within the flow channels and from the stack to the environment. The simplifying assumptions are identified and their carefully justified range of applicability to the problem at hand is established. This allows thermal radiation effects to be properly included in overall thermal modeling efforts with the minimum computational expense requirement. Second, we developed a series of reduced-order models for the transient heating and cooling of a cell, leading to a framework for optimization of these processes. The optimal design is one that minimizes heating time while maintaining thermal gradients below an allowable threshold. To this end, we formulated reduced order models (validated by rigorous CFD simulations) that yield simple algebraic design rules for predicting maximum thermal gradients and heating time requirements. Several governing dimensionless parameters and time scales were identified that shed light on the essential physics of the process. Finally, an analysis was performed to assess the degree of local thermal non-equilibrium (LTNE) within porous SOFC electrodes, and through a simple scaling analysis we discovered the parameter that gives an estimate of the magnitude of LTNE effects. We conclude that because of efficient heat transfer between the solid and gas in the microscale pores of the electrodes, the temperature difference between gas and solid is often negligible. However, if local variations in current density are significant, the LTNE effects may become significant and should be considered.