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Patent-backed hybrid cooling system
combines nanofluids and heat pipes to prevent battery overheating and reduce EV
fire risks in Indian conditions.
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The compact, energy-efficient design
offers a scalable solution for two-wheeler EVs, lowering maintenance costs and
enhancing long-term battery performance.
Pune: Researchers
at MIT World Peace University (MIT-WPU), Pune have developed a patented passive
hybrid cooling system—granted under the Indian patent “System for Thermal
Management of Battery of Vehicle” (Patent No. 202121029238)—that significantly
enhances thermal management in electric vehicle (EV) batteries. Designed to
improve both performance and safety, the system addresses the challenges posed
by India’s high-temperature conditions and rising EV fire incidents.
The research team includes Dr.
Vaibhav Deshmukh, Associate Professor, Department of Mechanical
Engineering; Dr. S. Radhakrishnan, Professor Emeritus & Director
Research, Department of Materials Science and Engineering; and Dr. Vaidehi
Deshmukh, Assistant Professor, Department of Electrical and Electronics
Engineering. They designed a hybrid passive cooling architecture that combines
high-efficiency heat pipes with a specially engineered nanofluid, offering a
pump-free, energy-efficient alternative to conventional EV battery cooling
systems.
What makes this patented
innovation particularly unique is its fully passive hybrid cooling mechanism
that operates entirely through natural convection and phase-change
processes—without the use of pumps, fans or any additional electrical power.
The integration of a custom-engineered nanofluid, enhanced with thermally
conductive nanoparticles and low-boiling-point liquids, enables rapid heat
extraction from battery hotspots. When paired with high-efficiency heat pipes,
the system maintains stable thermal conditions even in extreme environmental
temperatures, providing a high-reliability, energy-independent and inherently
safer alternative to current air- or liquid-based EV cooling technologies,
making it especially suited to India’s climatic conditions.
Unlike traditional cooling
systems, this patented technology removes heat rapidly using natural convection
and phase-change processes rather than forced circulation. By maintaining
stable battery temperature, the system significantly improves battery lifespan,
charging efficiency and user safety.
Highlighting the
significance of the breakthrough, Dr. Vaibhav Deshmukh said, “In an
environment such as India’s—with high ambient temperatures and rapidly growing
EV usage, the challenge isn’t just about performance, it is about safety first.
Our passive hybrid cooling system ensures that the battery pack remains within
safe thermal limits without drawing power from the vehicle’s system, thereby
enhancing both reliability and operational efficiency.”
Dr. S. Radhakrishnan
noted that the aim was to leapfrog existing technologies: “Our goal was to
enhance safety and reliability by eliminating active mechanical components that
may fail or draw additional energy, and deliver a robust solution tailored for
high-temperature markets and rising fire-risk concerns.”
Dr. Vaidehi Deshmukh
added: “By integrating a thermally enhanced nanofluid with a heat-pipe
architecture—and removing pumps or fans—we’ve addressed two of the biggest
challenges faced by OEMs: energy overhead and thermal hotspots. This
significantly strengthens the safety profile of EVs in markets like India.”
The relevance of the
innovation is underscored by rapidly accelerating EV adoption and rising
expectations around reliability. Industry forecasts indicate that the global
electric vehicle battery thermal management systems (BTMS) market, estimated at
approximately USD 5.41 billion in 2024, is projected to reach around USD 29.09
billion by 2030, reflecting a strong growth trajectory driven by demand for
longer range, faster charging and improved safety standards. In India, the
EV-battery cooling systems market is projected to grow from about USD 138
million in 2025 to nearly USD 470 million by 2034, while the broader Battery
Management System (BMS) market is expected to rise from approximately USD 199
million in 2024 to USD 8.39 billion by 2035.
At the same time, increasing
concerns around EV safety have brought thermal incidents to the forefront.
India’s EV penetration has reached around 7.8% in FY 2024-25, and media as well
as industry assessments frequently cite battery thermal runaway and insufficient
cooling as major pain-points contributing to fire-related risks—particularly in
two-wheelers and three-wheelers, which dominate the adoption curve. Although
consolidated national statistics on EV fire counts remain limited, expert
analyses emphasize the urgent need for more reliable thermal management systems
to avoid overheating and enhance consumer confidence.