May 8, 2025
The development of the battery cooling system for electric bicycles
The EcoE 5000W electric bike
Powerful Motor: EcoE is equipped with a 60V 5000W high-speed brushless motor. Due to different loads and road conditions, the electric bike drive system provides adjustable assistance, allowing you to stay healthy, relax, and exercise.
Accessories: This electric bike accessory set includes a rearview mirror, water bottle holder and bottle, a sturdy phone mount, and a waterproof phone pouch. The reinforced cargo rack allows you to easily carry extra items needed for your ride. Additionally, if you need more accessories, you can purchase a detachable storage rack, passenger safety seat, trailer, and more.
60V 32AH Battery: The bike is equipped with a high-capacity, removable 32AH battery, providing longer range per charge and over 1000 charge cycles. With pedal assist, the fat tire e-bike can travel 35-80 miles, depending on riding mode, load, and terrain. You can also purchase a spare battery for extended trips.
Comfort and Versatility: This fat tire electric bike comes with dual front suspension and rear shocks to reduce impact and strain during rides. Its 26-inch wheels, 4-inch tires, and SHIM 7-speed system offer excellent grip across diverse terrains. Front and rear disc brakes ensure safe, responsive stopping, whether on mountain trails or city streets.
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- Natural Cooling Stage: In the early days of the development of electric bicycles, the battery cooling mainly relied on natural cooling. This method dissipated heat through the convection of the natural wind between the battery box and the outside world. It had a simple structure and low cost, and did not require additional cooling equipment. However, its heat – dissipation effect was limited, with low heat generation, and there was no heating system. Using it in low – temperature environments would cause a significant decline in the battery’s range and accelerate the battery’s aging. It was only suitable for electric bicycles with small battery capacity and short range, such as some early models with small battery capacity and a range of about 100 km.
- Forced Air – Cooling Stage: With the increase in battery energy density, the heat generated by the battery increased, and forced air – cooling gradually became a heat – dissipation method in the transition stage. It enhanced heat dissipation by adding circulating air pipes inside the battery pack and opening ventilation ports in positions with high heat generation. Compared with natural cooling, forced air – cooling could provide more stable cooling air flow, but its heat – dissipation power was still low, and the heat – dissipation efficiency was poor. It was not suitable for high – range large – capacity battery packs. Moreover, with the increase in the IP67 waterproof rating requirements for battery packs in the national standard, forced air – cooling was gradually replaced by other heat – dissipation methods because it was difficult to meet this requirement.
- Liquid – Cooling Stage: The liquid – cooling technology, that is, the coolant circulation cooling, is a relatively advanced and widely used heat – dissipation method. Common structures include the serpentine – tube liquid – cooling system similar to that of Tesla and the bottom water – cooling of Audi e – tron. The liquid – cooling system usually includes refrigeration and heating devices, which can meet the refrigeration and heating requirements of the battery under different environmental temperatures and working conditions. Some liquid – cooling systems are also coupled with the thermal management circuit of the motor. Through a three – way valve, the heat of the battery pack is guided to the motor radiator, further improving the heat – dissipation efficiency and energy utilization rate. The liquid – cooling technology has a good heat – dissipation effect, which can effectively control the battery temperature and prolong the battery life, but it also has the problems of complex structure, high sealing requirements, and high cost1.
- Exploration Stage of Other Cooling Technologies:
- Direct Refrigerant Cooling: It uses refrigerant to directly cool the battery pack. This method has certain advantages in refrigeration efficiency and can quickly reduce the battery temperature to a certain extent. However, it has the problem of difficult temperature control of the battery cells. Because the temperature of the refrigerant may be too low, it is easy to cause uneven temperature of the battery cells. Moreover, a separate heating system is required to meet the requirements in low – temperature environments, so its application is not yet widespread1.
- Immersion Cooling: The battery is immersed in an insulating and heat – conducting material. Theoretically, it can make the battery cells and the cooling medium fully contact each other to achieve a good heat – dissipation effect, which can effectively control the battery temperature and inhibit the spread of thermal runaway. However, this technology has some technical problems in practical application, such as the selection of insulating materials and the sealing of the system, so it has not yet become the mainstream heat – dissipation technology1.
- Phase – Change Energy – Storage Cooling: It uses the characteristics of phase – change materials to absorb heat and melt, and release heat and solidify when switching between liquid and solid states to absorb and release heat. It can buffer thermal mutations, has a good effect on inhibiting the spread of thermal runaway, and can also play a certain role in heat preservation. However, the cost of phase – change materials is high, and adding phase – change materials will increase the weight of the battery pack and reduce the energy density. At present, there are still certain difficulties in productization1.
The following is a summary table:
| Stage | Cooling Method | Principle | Advantages | Disadvantages | Application |
|---|---|---|---|---|---|
| Natural Cooling Stage | Natural Cooling | Heat dissipation by convection of natural wind between battery box and outside world | Simple structure, low cost | Limited heat – dissipation effect, range attenuation in low temperature, easy battery aging | Early electric bicycles with small battery capacity and short range |
| Forced Air – Cooling Stage | Forced Air – Cooling | Increase circulating air pipes and vents in battery pack, use fans to promote air flow for heat dissipation | More stable cooling air flow than natural cooling | Low heat – dissipation power, poor efficiency, not suitable for high – range batteries, difficult to meet waterproof rating requirements | As a transition – stage method, once applied to some electric bicycles |
| Liquid – Cooling Stage | Liquid Cooling | Coolant circulates in the battery system, exchanges heat with the battery cells to take away heat | Good heat – dissipation effect, can control temperature, prolong battery life, can be coupled with motor thermal management | Complex structure, high sealing requirements, high cost | Widely used at present, such as some high – end electric bicycles |
| Exploration Stage of Other Cooling Technologies | Direct Refrigerant Cooling | Use refrigerant to directly cool the battery pack | High refrigeration efficiency, can quickly cool down | Difficult to control the temperature of battery cells, need a separate heating system | Not widely applied |
| Immersion Cooling | Immerse the battery in an insulating and heat – conducting material for heat dissipation | Theoretically good heat dissipation, can inhibit thermal runaway | Technical problems in implementation, such as insulation and sealing | Not the mainstream technology | |
| Phase – Change Energy – Storage Cooling | Use the phase – change characteristics of phase – change materials to absorb and release heat | Can buffer thermal mutations, inhibit thermal runaway, have heat – preservation effect | Expensive materials, weight gain reduces energy density, difficult to productize | In the stage of research and small – scale application |
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5000W Dual Motor Electric Bike for Adults 52MPH with 60V32A, 26×4 Fat Tire All Terrain Ebikes, Full Suspension E Bike, SHM 7-Speed Gear Electric Bicycle
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