Despite its drawbacks, air cooling remains a viable solution when simplicity, low cost and ease of integration outweigh the need for high thermal precision. Liquid cooling is one of the most widely adopted thermal management strategies for modern battery systems due to its excellent balance of performance and practicality.
Nissan’s first-generation Leaf, for example, relied on ambient air flow. However, a 100 kWh battery can generate on the order of 5 kW of waste heat under heavy load, which requires more efficient liquid-cooling system. In practice, air-cooled EV packs are limited to very low-power use.
It uses a liquid coolant, typically a water-glycol mixture, that flows through channels or cold plates integrated within or around the battery pack. This method offers significantly higher heat transfer capacity compared to air cooling, resulting in more uniform cell temperatures, improved battery efficiency and extended lifespan.
Air-cooled systems use ambient air flow - fans or natural convection - to carry heat away from the cells. They are simple and low-cost, since no coolant, plumbing or pumps are needed. Air cooling avoids leak hazards and extra weight of liquids. As a result, smaller or lower-power battery installations often rely on air-cooled designs.
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