Hybrid liquid–PCM thermal management for high–capacity lithium–ion batteries under fast charging: A parametric comparative study
The necessity for effective battery thermal management systems (BTMS) has increased due to the growing reliance on lithium–ion batteries, particularly in electric vehicles (EVs). Due to the substantial heat generation caused by fast charging, efficient thermal regulation is required to keep operatin...
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| Main Authors: | , , , , , , |
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| Format: | Article |
| Language: | English |
| Published: |
Elsevier
2025-09-01
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| Series: | Results in Engineering |
| Subjects: | |
| Online Access: | http://www.sciencedirect.com/science/article/pii/S2590123025027410 |
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| Summary: | The necessity for effective battery thermal management systems (BTMS) has increased due to the growing reliance on lithium–ion batteries, particularly in electric vehicles (EVs). Due to the substantial heat generation caused by fast charging, efficient thermal regulation is required to keep operating temperatures below 40°C and restrict temperature variation to less than 5°C, guaranteeing battery performance, safety, and longer battery life. This study examines three BTMS techniques—passive cooling with phase change materials (PCM), indirect liquid cooling and hybrid systems—applied to an 8–cell, 105 Ah lithium–ion battery pack. A 3D numerical model is developed using COMSOL Multiphysics to evaluate the system under 1C, 2C and 3C charging rate. Systems underwent extensive parametric analysis to optimize them. Variables like battery arrangement (8 × 1 and 4 × 2), tube length, tube configuration (vertical, horizontal, parallel wavy), flow regime (laminar/turbulent), and the usage of an aluminum cold plate with water as a coolant were all investigated for liquid cooling. In order to evaluate thermal performance for the PCM system, paraffin wax reinforced with graphite was tested in a range of thicknesses. The liquid cooling arrangement with three inlets and a wavy tube architecture reached a peak temperature of 36.8°C and a temperature variation of 1.8°C at a 3C charging rate, according to the results. Under the same conditions, the PCM–based method achieved 42°C with a variation of only 1.4°C, demonstrating improved temperature uniformity. A hybrid cooling system was created to combine the low peak temperatures of liquid cooling with the uniformity of PCM in order to maximize the benefits of both approaches. The results show that the hybrid BTMS achieves a maximum battery temperature of 36.7 °C and reduces temperature variation to 1.0 °C. Additionally, a cost–performance analysis highlights the hybrid system's ability to provide superior thermal regulation at a modest increase in weight and implementation cost. By addressing significant thermal issues during rapid charging, this hybrid technology extends the longevity and dependability of high–capacity lithium–ion batteries. |
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| ISSN: | 2590-1230 |