Development of a mini-channel and metal foam-assisted static immersion cooling and preheating system for electric vehicle battery thermal management
This study developed an innovative immersion battery thermal management system (BTMS) that incorporates mini-channels and metal foam to address the limitations of conventional indirect liquid-cooled BTMSs under extreme conditions. The proposed system leveraged the superior thermal conductivity of th...
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| Format: | Article |
| Language: | English |
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Elsevier
2025-06-01
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| Series: | Case Studies in Thermal Engineering |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2214157X25004058 |
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| author | Hongseok Choi Hyuntae Kim Piljun Park Hoseong Lee |
| author_facet | Hongseok Choi Hyuntae Kim Piljun Park Hoseong Lee |
| author_sort | Hongseok Choi |
| collection | DOAJ |
| description | This study developed an innovative immersion battery thermal management system (BTMS) that incorporates mini-channels and metal foam to address the limitations of conventional indirect liquid-cooled BTMSs under extreme conditions. The proposed system leveraged the superior thermal conductivity of the metal foam and the structural advantages of mini-channels to enhance battery cooling and preheating performance. The results showed that under fast-charging conditions, the maximum battery temperature under the proposed system was reduced from 50.9 °C to 39.8 °C, compared with the traditional system. The temperature difference also decreased to 6.4 K with MCMF system, while forced immersion system showed 9.6 K. In preheating scenarios, the MCMF system increased the minimum battery temperature from 0.6 °C to 11.5 °C within 10 min. The initial MCMF system was developed with optimal metal foam properties and coolant operating strategies, which resulted in enhanced battery cooling, preheating, and hydraulic performances. Furthermore, the system demonstrated effective thermal management at extremely high and extremely low temperatures. Hence, the proposed BTMS resulted in significant improvements in terms of thermal performance and energy efficiency, thereby highlighting its potential to enhance the thermal management of batteries in electric vehicles under various temperature conditions. |
| format | Article |
| id | doaj-art-d97e74273df84ce9a0a5aa4deb2b10d6 |
| institution | OA Journals |
| issn | 2214-157X |
| language | English |
| publishDate | 2025-06-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Case Studies in Thermal Engineering |
| spelling | doaj-art-d97e74273df84ce9a0a5aa4deb2b10d62025-08-20T02:13:40ZengElsevierCase Studies in Thermal Engineering2214-157X2025-06-017010614510.1016/j.csite.2025.106145Development of a mini-channel and metal foam-assisted static immersion cooling and preheating system for electric vehicle battery thermal managementHongseok Choi0Hyuntae Kim1Piljun Park2Hoseong Lee3Department of Mechanical Engineering, Korea University, 409 Innovation Hall Bldg, Anam-Dong, Seongbuk-Gu, Seoul, Republic of KoreaDepartment of Mechanical Engineering, Korea University, 409 Innovation Hall Bldg, Anam-Dong, Seongbuk-Gu, Seoul, Republic of KoreaDepartment of Automotive Convergence, Korea University, 409 Innovation Hall Bldg, Anam-Dong, Seongbuk-Gu, Seoul, Republic of KoreaDepartment of Mechanical Engineering, Korea University, 409 Innovation Hall Bldg, Anam-Dong, Seongbuk-Gu, Seoul, Republic of Korea; Corresponding author.This study developed an innovative immersion battery thermal management system (BTMS) that incorporates mini-channels and metal foam to address the limitations of conventional indirect liquid-cooled BTMSs under extreme conditions. The proposed system leveraged the superior thermal conductivity of the metal foam and the structural advantages of mini-channels to enhance battery cooling and preheating performance. The results showed that under fast-charging conditions, the maximum battery temperature under the proposed system was reduced from 50.9 °C to 39.8 °C, compared with the traditional system. The temperature difference also decreased to 6.4 K with MCMF system, while forced immersion system showed 9.6 K. In preheating scenarios, the MCMF system increased the minimum battery temperature from 0.6 °C to 11.5 °C within 10 min. The initial MCMF system was developed with optimal metal foam properties and coolant operating strategies, which resulted in enhanced battery cooling, preheating, and hydraulic performances. Furthermore, the system demonstrated effective thermal management at extremely high and extremely low temperatures. Hence, the proposed BTMS resulted in significant improvements in terms of thermal performance and energy efficiency, thereby highlighting its potential to enhance the thermal management of batteries in electric vehicles under various temperature conditions.http://www.sciencedirect.com/science/article/pii/S2214157X25004058Battery thermal management systemMetal foamImmersion systemSingle-phaseDielectric fluid |
| spellingShingle | Hongseok Choi Hyuntae Kim Piljun Park Hoseong Lee Development of a mini-channel and metal foam-assisted static immersion cooling and preheating system for electric vehicle battery thermal management Case Studies in Thermal Engineering Battery thermal management system Metal foam Immersion system Single-phase Dielectric fluid |
| title | Development of a mini-channel and metal foam-assisted static immersion cooling and preheating system for electric vehicle battery thermal management |
| title_full | Development of a mini-channel and metal foam-assisted static immersion cooling and preheating system for electric vehicle battery thermal management |
| title_fullStr | Development of a mini-channel and metal foam-assisted static immersion cooling and preheating system for electric vehicle battery thermal management |
| title_full_unstemmed | Development of a mini-channel and metal foam-assisted static immersion cooling and preheating system for electric vehicle battery thermal management |
| title_short | Development of a mini-channel and metal foam-assisted static immersion cooling and preheating system for electric vehicle battery thermal management |
| title_sort | development of a mini channel and metal foam assisted static immersion cooling and preheating system for electric vehicle battery thermal management |
| topic | Battery thermal management system Metal foam Immersion system Single-phase Dielectric fluid |
| url | http://www.sciencedirect.com/science/article/pii/S2214157X25004058 |
| work_keys_str_mv | AT hongseokchoi developmentofaminichannelandmetalfoamassistedstaticimmersioncoolingandpreheatingsystemforelectricvehiclebatterythermalmanagement AT hyuntaekim developmentofaminichannelandmetalfoamassistedstaticimmersioncoolingandpreheatingsystemforelectricvehiclebatterythermalmanagement AT piljunpark developmentofaminichannelandmetalfoamassistedstaticimmersioncoolingandpreheatingsystemforelectricvehiclebatterythermalmanagement AT hoseonglee developmentofaminichannelandmetalfoamassistedstaticimmersioncoolingandpreheatingsystemforelectricvehiclebatterythermalmanagement |