Thermal control systems for power sources for electric aircraft


Аuthors

Vasiliev L. L.1*, Zhuravlyov A. S.2**, Vasiliev L. L.2

1. A. V. Luikov Heat and Mass Transfer Institute of NAS of Belarus, 15 P. Brovka Str., Minsk, 220072, Belarus
2. Limited Liability Company "LED Intech", 220113, Republic of Belarus, Minsk, Melezha St., 1

*e-mail: lvasil@hmti.ac.by
**e-mail: zhuravl@hmti.ac.by

Abstract

Unmanned aerial vehicles (UAVs) and electric vertical takeoff and landing (eVTOL) aircraft are becoming highly popular in civil and commercial industries. In these aircraft, electrical energy storage systems (batteries) are key components for propulsion. Using batteries in satellites, UAVs, and eVTOLs creates different requirements for stored energy, power capability, charge/discharge speeds, and thermal stability. Battery temperature remains a major problem. High heat generation and overheating reduce safety, lower efficiency, and destroy battery cells faster. Therefore, engineers need compact and high-performance Battery Thermal Management Systems (BTMS) that fit into small spaces and add very little weight.

Air cooling is the most common method for UAVs because it is simple and lightweight. However, from a physical standpoint, air cooling is the least effective method. It cannot handle the high heat from mo-dern, high-power battery cells. Adding a radiator helps remove heat, but it increases weight and vo-lume, which reduces the aircraft's performance. Liquid cooling removes heat much better. However, it requires extra parts, including pipes, a pump, a fluid tank, and a radiator. Additionally, the pump consumes electricity from the battery.

Two-phase heat transfer methods are a promising solution for better BTMS efficiency. These systems use a working fluid that absorbs and releases latent heat. Specifically, heat-pipe systems combine high cooling performance with passive operation, small size, and low weight. Among these, flat-panel pulsating heat pipes (PHPs) are excellent candidates for future UAV and eVTOL projects because they have a simple design, small volume, low weight, and low cost. This review article explains how lithium-ion cells generate heat and how internal heat-transfer processes work. It analyzes recent engineering advances and remaining challenges in thermal management, with a special focus on new two-phase solutions. Finally, it shows future research directions to improve system safety and efficiency. This paper is a helpful resource for researchers, engineers, and industry professionals who want to optimize battery cooling systems.

Keywords:

UAV, eVTOL, thermal control ,battery thermal management system (BTMS), heat pipes, thermosyphon

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