Hybrid thermal management system of lithium-ion batteries combing phase change material with liquid cooling under high-rate operation

IF 4.9 2区工程技术 Q1 ENGINEERING, MECHANICAL

International Journal of Thermal Sciences Pub Date : 2025-07-07 DOI:10.1016/j.ijthermalsci.2025.110117

Gang Wu , Hao Wu , Bo Huang , Wenhao Zhu

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引用次数: 0

Abstract

The high-rate operation of lithium-ion batteries induces rapid heat accumulation, posing critical challenges for thermal safety and longevity. This study presents a hybrid thermal management system integrating phase change material (PCM) with liquid cooling under high-rate operation. Key parameters including coolant flow rate, temperature, channel geometry, and PCM configuration are systematically optimized at a 5C discharge rate. An S-shaped channel with a 2mm × 4 mm cross-section is optimized, achieving a peak temperature of 47.5 °C (below the 50 °C safety threshold) and a PCM liquid fraction of 0.4, while maintaining a maximum temperature difference of 5.5 °C. Enhanced convective cooling at 0.06 m/s flow velocity can balance the cooling efficiency and energy consumption. The length of cross-sectional optimization (4 mm cross-section, triple-bend structure) can minimise thermal gradients. Multi-cell PCM encapsulation strategies improve temperature performance ensuring thermal safety. These results demonstrate that the novel hybrid thermal management system can effectively enhance temperature uniformity. It offers a scalable solution for high-power battery systems in electric vehicles and energy storage applications.

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高倍率运行下相变材料与液冷相结合的锂离子电池混合热管理系统

锂离子电池的高倍率运行导致热量快速积累，对热安全和寿命提出了严峻的挑战。本研究提出一种结合相变材料（PCM）与液体冷却的混合热管理系统。关键参数包括冷却剂流量、温度、通道几何形状和PCM配置在5C放电速率下进行了系统优化。优化了横截面为2mm × 4mm的s形通道，峰值温度为47.5℃（低于50℃的安全阈值），PCM液体分数为0.4，最大温差为5.5℃。在0.06 m/s流速下增强对流冷却可以平衡冷却效率和能耗。截面长度优化（4毫米截面，三弯结构）可以最小化热梯度。多单元PCM封装策略提高了温度性能，确保热安全。结果表明，该混合热管理系统可以有效地提高温度均匀性。它为电动汽车和储能应用中的大功率电池系统提供了可扩展的解决方案。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

International Journal of Thermal Sciences 工程技术-工程：机械

CiteScore

8.10

自引率

11.10%

发文量

531

审稿时长

55 days

期刊介绍： The International Journal of Thermal Sciences is a journal devoted to the publication of fundamental studies on the physics of transfer processes in general, with an emphasis on thermal aspects and also applied research on various processes, energy systems and the environment. Articles are published in English and French, and are subject to peer review. The fundamental subjects considered within the scope of the journal are: * Heat and relevant mass transfer at all scales (nano, micro and macro) and in all types of material (heterogeneous, composites, biological,...) and fluid flow * Forced, natural or mixed convection in reactive or non-reactive media * Single or multi–phase fluid flow with or without phase change * Near–and far–field radiative heat transfer * Combined modes of heat transfer in complex systems (for example, plasmas, biological, geological,...) * Multiscale modelling The applied research topics include: * Heat exchangers, heat pipes, cooling processes * Transport phenomena taking place in industrial processes (chemical, food and agricultural, metallurgical, space and aeronautical, automobile industries) * Nano–and micro–technology for energy, space, biosystems and devices * Heat transport analysis in advanced systems * Impact of energy–related processes on environment, and emerging energy systems The study of thermophysical properties of materials and fluids, thermal measurement techniques, inverse methods, and the developments of experimental methods are within the scope of the International Journal of Thermal Sciences which also covers the modelling, and numerical methods applied to thermal transfer.