A novel multilayer composite structure based battery thermal management system

Thermal management characteristics of a novel cylindrical lithium-ion battery module using liquid cooling, phase change materials, and heat pipes

Performance of a combined battery thermal management system with dual-layer phase change materials and air cooling technologies

Experimental study of phase transition heat of composite thermal energy storage materials paraffin wax/expanded graphite

Phase change materials for lithium-ion battery thermal management systems: A review

Numerical study on the effect of gallium filling on the cooling performance of battery thermal management system

The development of Lithium-ion (Li-ion) batteries has led to progress in the electronics, automobile and space applications sectors. At present lithium-ion battery is an essential part of Electric Vehicles (EVs) because of its inherent advantages such as high specific power, long battery life, low auto discharge rate, no memory effect and high nominal voltage. Most of the batteries generate large amount of heat during discharge phase and the operational temperatures significantly affects the efficiency and reliability of the batteries. Therefore, an efficient battery thermal management system (BTMS) is the need of the hour. The phase change material (PCM)-based BTMS is an effective and promising cooling strategy for better performance of Li-ion batteries. The PCM can absorb/release large amount of latent heat during the charge (fusion) /discharge (solidification) process, capable of maintaining relatively constant temperature of the battery system. Most PCMs have low thermal conductivity, leading to slow charging and discharge rates that can lead to rise in temperature of the system. Metal foam with high thermal conductivity can be used in conjunction with PCMs to amplify the thermal conductivity, thereby ensuring uniform temperature distribution across the cell and accelerate the melting processes. This comprehensive review paper mainly focusses on the research progresses, challenges and prospects of the PCM embedded metal foam-based BTMS. Major focus of this review is the study of PCMs used along with copper, aluminium and nickel metal foams for improving the thermal performance. Effects of porosity and pore density on heat transfer performance of various PCMs are elaborated. Finally, conclusions are drawn and recommendations highlighting the research gap in this area are presented.

Advances in the improvement of thermal-conductivity of phase change material-based lithium-ion battery thermal management systems: An updated review

In recent years, large power batteries have been widely used not only in automobiles and other vehicles but also in maritime vessels. The thermal uniformity of large marine battery packs significantly affects the performance, safety, and longevity of the electric ship. As a result, the thermal management of large power batteries has become a crucial technical challenge with traditional battery management system (BMS) that cannot effectively solve the battery heating problem caused by electrochemical reactions and joule heating during operation. To address this gap, a battery thermal management system (BTMS) has been newly designed. This article presents the design of a large marine battery pack, which features a liquid cooling system integrated into both the bottom and side plates of each pack. The flow plate is constructed from five independent units, each connected by manifold structures at both ends. These connections ensure the formation of a stable and cohesive flow plate assembly. Although research on the BTMS is relatively advanced, there is a notable lack of studies examining the effects of liquid temperature, flow rate, and battery discharge rate on the temperature consistency and uniformity of large marine battery packs. This work seeks to design the cooling system for the battery pack and analyzes the impact of the temperature, flow rate, and battery discharge rate of the liquid fluid on the consistency and uniformity of the battery pack temperature on the overall structure of the battery pack. It was found that, in low discharge conditions, there was good temperature consistency between the battery packs and between the different batteries within the battery pack, and the temperature difference did not exceed 1 °C. However, under high discharge rates, a C-rate of 4C, there might have been a decrease in temperature consistency; the temperature rise rate even exceeded 50% compared to when the discharge rate was low. The flow rate in the liquid flow characteristics had little effect on the temperature consistency between the batteries and the temperature uniformity on the battery surface, and the temperature fluctuation was maintained within 1 °C. Conversely, the liquid flow temperature had little effect on the temperature distribution between the batteries, but it caused discrepancies in the surface temperature of the batteries. In addition, the liquid flow temperature could cause the overall temperature of the battery to increase or decrease, which also occurs under different discharge rates.

Thermal Behavior of Lithium-Ion Batteries Using Graphite-Enhanced Phase Change Composites

The present study has been executed to clarify the advantage of using latent thermal storage integrated with a back pass solar air heater (SAH). The purpose of this study is to design, fabricate and evaluate the performance of SAH with integrated nanoparticles enhanced phase change material (PCM) absorber storage system. Three different SAH configurations have been designed and studied; without thermal storage, with thermal storage using paraffin wax as a PCM and with thermal storage using Al2O3-paraffin wax. A three-dimensional Navier-Stokes equation coupled with the energy balance equation is solved using the computational fluid dynamics (CFD) software program to implement numerical computations. The numerical analysis is conducted to determine the optimum collector dimensions in terms of length (L), width (W) and depth of air flow channel (Hch) at air mass flow rate of 0.03 kg/s and solar irradiance of 1000 W/m2. Results obtained from the numerical analysis indicate that the collector dimensions of (L = 1.8 m, W = 0.7 m, Hch = 0.07 m) which are the best design. The numerical results show that the SAH with Al2O3-paraffin wax have the thermal efficiency ranged between 73 % and 78 % with air temperature difference from 25 °C to 46.6 °C when the solar irradiance of 1000 W/m2 at the air mass flow rates of 0.03 kg/s and 0.06 kg/s, respectively. The experimental setup is constructed using these optimum dimensions for each configuration and validated using the numerical results. All configurations are fabricated and tested outdoor under the Iraq climatic conditions according to ASHRAE standard tests at different air mass flow rates. The two steps method is used to prepare the mixture of nanoparticles with PCM and ultrasonic device is used to suspend the nanoparticles in the PCM. The experimental results show that the SAH with Al2O3-paraffin wax has the highest daily performance and thermal efficiency followed by SAH with pure paraffin wax and SAH without storage. Moreover, the discharging time in the SAH with pure paraffin wax of heat stored took 5.5, 5, 4.5 and 4 hours at the air mass flow rate 0.03, 0.04, 0.05 and 0.06 kg/s, respectively. As for the SAH with Al2O3-paraffin
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\nwax, the discharge time are 5, 4.5, 4 and 3.5 hours at the air mass flow rates of 0.03, 0.04, 0.05 and 0.06 kg/s, respectively. The experimental results also show that increment in the thermal conductivity of PCM with the dispersion 1wt. % Al2O3 which led to raise the outlet air temperature and thermal efficiency of the SAH compared to SAH with pure paraffin wax. In addition, good agreement are obtained when comparing between the numerical and experimental results. It was the average differences in percentage on outlet air temperatures obtained in the numerical and experimental results from 2.11 % to 2.47 % and on the thermal efficiency from 2.70% to 3.50 %, respectively.

The low thermal conductivity of phase change material (PCM) critically constrains the cooling performance of PCM-based battery thermal management system (BTMS). To address this limitation, embedding high-thermal-conductivity fins into PCM was recently explored. However, it may increase the overall BTMS mass, degrading vehicle performance. Therefore, a quantitative evaluation of the effects of fin design on cooling performance and system mass is required. In this study, the effects of fin design factors in a PCM–fin structured BTMS on the maximum cell temperature and BTMS mass was analyzed using design of experiments (DoE) and analysis of variance (ANOVA). To characterize BTMS thermal behavior, a numerical model was developed by applying thermal fluid partial differential equations (PDEs) with the enthalpy–porosity method to represent the phase change of the PCM. Fin number, thickness, and angle were selected as design factors; responses were calculated through thermal fluid analysis. The results showed a trade-off between thermal performance and mass across all design factors. The number of fins had the greatest effect on maximum cell temperature (78.27%) but less on mass (28.85%). Fin thickness moderately affected temperature (16.71%) but strongly increased mass (63.93%). Fin angle had minimal impact, 4.10% on temperature and 3.10% on mass.

A novel heat pipe assisted separation type battery thermal management system based on phase change material

This work examines the capacity of titanium dioxide (TiO2) nanoparticles to improve the thermal efficiency and characteristics of phase change materials (PCMs) in latent heat thermal energy storage (LHTES) systems. The TiO2 nanoparticles were introduced in varying concentrations of 0.5%, 1.0%, 1.5% and 2.0%. The effect of varying concentrations of TiO2 nanoparticles on thermal conductivity (TC), melting and solidification time, and charging and discharging efficiency was studied and compared with paraffin wax at different flow rates (0.5 LPM, 1.0 LPM and 1.5 LPM). A total of 4 samples were prepared using a magnetic stirrer. Fourier Transform Infrared Spectroscopy (FTIR) is employed to analyze chemical interactions, while Field Emission Scanning Electron Microscopy (FESEM) is used to analyze the distribution of nanoparticles in the PCM matrix. The tests demonstrate that the TiO2 nanoparticles are evenly distributed inside the PCM matrix and have no harmful chemical interactions. In addition, Thermogravimetric Analysis (TGA) is utilized to assess the thermal stability of the nano-enhanced PCM (NEPCM). The TGA results demonstrate the improved resistance to heat degradation of the NEPCM, which is crucial for the long-term operation of the LHTES system. Each sample’s thermal conductivity and pure paraffin wax were also checked using a hot disk TPS 500 instrument. The findings demonstrate that the addition of TiO2 nanoparticles enhances the thermal conductivity of the PCM by 35%, 53%, 69.5%, and 88% at 0.5, 1.0, 1.5, and 2.0% when compared with pristine PCM. The improved thermal conductivity resulted in faster heat transfer rates during the charging and discharging. Compared with paraffin wax, at an HTF flow rate of 0.01 Kg s−1, the NEPCM containing 0.5% TiO2 improved the charging, discharging, and overall efficiencies around 2.89%, 5.21%, and 2.25%, respectively. This research offers vital knowledge on the advantages of using TiO2 nanoparticles to enhance the thermal efficiency and behaviour of PCMs in LHTES systems. This opens up possibilities for more effective and environmentally friendly energy storage solutions in applications like batteries, food storage, buildings, HVAC, etc.

Efficient thermal management of high‐power lithium‐ion batteries (LiBs) is critical for ensuring safety, longevity, and performance in electric vehicles (EVs). Battery thermal management systems (BTMS) play a crucial role in regulating temperature, as LiBs are highly sensitive to thermal fluctuations. Excessive heat generation during charging and discharging can degrade battery performance, reduce lifespan, and pose safety risks. Traditional cooling methods, such as air and liquid cooling, often require additional power and complex components, making them less effective for high‐energy–density batteries. As a result, recent advancements focus on immersion, indirect, and hybrid cooling solutions. Among these, phase change material (PCM)‐based BTMS has emerged as a promising passive cooling approach. PCMs efficiently absorb and store heat, maintaining optimal battery temperature without external power. Their thermal performance is further enhanced by integrating expanded graphite (EG) fillers, metal foams, or fins, improving heat dissipation. This review examines recent progress (2019–2024) in BTMS technologies, with a particular focus on PCM applications in fast‐charging conditions. It also discusses BTMS performance under extreme environments, such as high temperatures, sub‐zero conditions, and abuse scenarios. Future research directions are highlighted to optimize BTMS for next‐generation EVs, ensuring improved battery safety, efficiency, and thermal stability.

This study presents a numerical investigation of a hybrid battery thermal management system (BTMS) that integrates phase change material (PCM) and heat pipes (HP) to control the thermal behavior of lithium‐ion batteries under varying discharge rates and thermal boundary conditions. The model is validated against experimental and published numerical results, achieving a temperature deviation within ±1.2% and a root mean square error below 1.5 K. Simulations of bare batteries reveal critical temperature rise above 345 K at a 4 C discharge rate under low convective cooling (heat transfer coefficient, HTC = 15 W m−2 K−1), risking thermal runaway. The use of PCM alone reduces peak temperature by 10–12 °C, while PCM combined with HP enhances thermal regulation, reducing maximum temperature by an additional 3–4 °C and improving surface temperature uniformity (ΔT reduction up to 2 K). At HTC = 60 W m−2 K−1, further temperature reductions of 6–8 °C are observed, with improved PCM re‐solidification. The hybrid BTMS maintains battery temperatures below 324 K and ΔT < 5 K under extreme loading. These results confirm that PCM + HP systems significantly enhance thermal safety, uniformity, and performance, offering a viable thermal solution for electric vehicle and grid‐scale energy storage systems.