ELECTRA - Enhanced Liquid cooling for ElectriC Traction systems in Recreational Aviation

Details

ERC sector: PE8 - Products and Processes Engineering
ERC subsector: PE8_7 - Mechanical engineering
Project start date: 06/11/2024
CUP: D53C24003970006
Financial support received: €61.121,00

Description and purpose

This research aims to develop an innovative Battery Thermal Management System (BTMS) for electric vehicles (with a particular focus on electric aircraft) based on the combination of two high-efficiency passive two-phase heat transfer techniques. Aircraft batteries operate under harsh electrical and environmental conditions, where high power demand generates intense heat fluxes, rapidly raising temperatures and reducing performance and lifespan. To address this, the project focuses on an advanced Battery Thermal Management System. The target application is Light Sport Aircraft (LSA, MTOM < 600 kg), particularly for training purposes where limited flight time aligns with battery storage capacity. The proposed BTMS submerges Li-Ion cells in a low-boiling dielectric fluid, enabling efficient heat transfer from the battery to the frame and then to the environment. Additionally, Pulsating Heat Pipes (PHPs)—simple, cost-effective, passive two-phase loops—are integrated within the cell pack and submerged in the fluid. Their compactness, flexibility, low weight, and ability to function without external power make them ideal for aviation. PHPs are designed to handle thermal peaks that risk complete fluid evaporation, gas overheating, and dangerous pressure rise, thus enhancing cooling efficiency and system safety.

Website: https://www.ingeo.unich.it/pagina-electra-enhanced-liquid-cooling-for-electric-traction-systems-in-recreational-aviation-2035

Purpose

This project addresses sustainable mobility by developing an innovative cooling system for electric batteries (with particular attention to aircraft batteries). A key challenge is managing the high heat produced by Li-Ion cells during demanding phases such as take-off and climb, as overheating reduces performance and risks malfunction. The proposed Battery Thermal Management System is based on submerging cells in a low-boiling dielectric fluid for efficient heat transfer. Pulsating Heat Pipes are added to control thermal peaks, promote fluid re-condensation, and prevent dangerous pressure rises. The system is fully passive, requiring no extra power for coolant circulation, improving compactness and reliability.

Expected results

The main scientific tasks of the proposed research project can be summarized as follows:

- identification of the key parameters that influence the behavior of the submerged battery here investigated;

- design of an innovative cooling system based on the coupling of low boiling dielectric fluids and PHPs for the thermal management of electric batteries;

- develop of an innovative estimation procedure of PHPs local performance, tailored for the specific application;

- production of a prototype of the designed thermal management system;

- experimental characterization of the batteries equipped with the designed thermal management system.

Achieved results

The initial results have been published and can be found in the following articles:

Cattani, L., Sacchelli, F., & Bozzoli, F. (2025). Enhanced Passive Thermal Management for Electric Vehicle Batteries Using a 3D Pulsating Heat Pipe. Energies, 18(9), 2306.
Sacchelli, F., Cattani, L., & Bozzoli, F. (2025). Study of the thermal performance of a new dual-phase cooling strategy in electric vehicle battery systems. Energies, 18(18), 4937.

They were also presented at the following conferences:

Cattani, L.; Sacchelli, F.; Bozzoli, F.; Soldati, A.; Musetti, A. Experimental Evaluation of a Passive Dual Two-Phase Cooling System for Ev Batteries Using a Dielectric Fluid and a Pulsating Heat Pipe. (poster presentation) - THERMINIC Conference 2025 – Naples, September 24-26, 2025

Sacchelli, F.; Cattani, L.; Bozzoli, F. Experimental evaluation of a high-performance dual two-phase cooling system for ev batteries, (oral presentation), 42nd UIT Heat Transfer Conference, Florence, 23rd - 25th June 2025.