Experimental and numerical investigation of 3D-printed macro-encapsulated PCM variants for battery thermal management systems

IF 5.4 3区工程技术 Q2 ENERGY & FUELS

Thermal Science and Engineering Progress Pub Date : 2025-09-25 DOI:10.1016/j.tsep.2025.104151

Bilal Kursuncu , Abid Ustaoglu , Ferhat Yildiz , Junnosuke Okajima , Ahmet Sarı , Osman Gencel , Orhan Uzun

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引用次数: 0

Abstract

This study presents a novel battery thermal management system (BTMS) design, which is numerically and experimentally examined, utilizing macro-encapsulation with 3D-printed polylactic acid (PLA) material to store phase change materials (PCM). A distinctive contribution of this study is the implementation of macro-encapsulated PCM using 3D printing, which offers a leak-proof, passive, and energy-free BTMS solution. This approach addresses sealing issues and improves battery thermal management. Capric acid (CA) and microencapsulated PCM (ME) are compared to the base case with an air gap under different charge and discharge conditions. The high specific heat capacity and phase change temperature of CA-PCM enable effective battery thermal management. The BTMS effectively maintains battery temperatures within the optimal range, extending battery life. Under all charging and discharging conditions, battery temperatures in CA-BTMS are consistently lower than those in Air BTMS. The CA BTMS temperature is 37.83 °C in the 1.72C charging condition, compared to 38.09 °C in the Air BTMS system. Similarly, the CA BTMS battery temperature is 36.18 °C under the same C-rate discharge condition, whereas the Air BTMS temperature is 36.39 °C. Reduced internal resistance in the CA case enhances voltage stability and energy efficiency, yielding higher average voltage values during charge and discharge cycles. CA BTMS exhibits lower voltage differences during charging than Air BTMS, and these differences are further reduced to 0.019 V, 0.012 V, and 0.01 V during discharge.

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电池热管理系统3d打印宏封装PCM变体的实验与数值研究

本研究提出了一种新的电池热管理系统（BTMS）设计，并进行了数值和实验验证，该系统利用3d打印聚乳酸（PLA）材料的宏观封装来存储相变材料（PCM）。这项研究的一个独特贡献是使用3D打印实现宏封装PCM，这提供了一个防泄漏、无源和无能源的BTMS解决方案。这种方法解决了密封问题，并改善了电池的热管理。在不同的充放电条件下，比较了癸酸（CA）和微胶囊化PCM （ME）在具有气隙条件下的基本情况。CA-PCM具有较高的比热容和相变温度，可以实现有效的电池热管理。BTMS有效地将电池温度保持在最佳范围内，延长电池寿命。在所有充放电条件下，CA-BTMS的电池温度始终低于Air BTMS。在1.72C充电条件下，CA BTMS温度为37.83℃，而Air BTMS系统的温度为38.09℃。同样，在相同C倍率放电条件下，CA BTMS电池温度为36.18°C，而Air BTMS电池温度为36.39°C。减少内阻在CA的情况下，提高电压稳定性和能源效率，在充电和放电周期产生更高的平均电压值。CA BTMS在充电时的电压差比Air BTMS低，放电时的电压差进一步减小到0.019 V、0.012 V和0.01 V。

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

Thermal Science and Engineering Progress Chemical Engineering-Fluid Flow and Transfer Processes

CiteScore

7.20

自引率

10.40%

发文量

327

审稿时长

41 days

期刊介绍： Thermal Science and Engineering Progress (TSEP) publishes original, high-quality research articles that span activities ranging from fundamental scientific research and discussion of the more controversial thermodynamic theories, to developments in thermal engineering that are in many instances examples of the way scientists and engineers are addressing the challenges facing a growing population – smart cities and global warming – maximising thermodynamic efficiencies and minimising all heat losses. It is intended that these will be of current relevance and interest to industry, academia and other practitioners. It is evident that many specialised journals in thermal and, to some extent, in fluid disciplines tend to focus on topics that can be classified as fundamental in nature, or are ‘applied’ and near-market. Thermal Science and Engineering Progress will bridge the gap between these two areas, allowing authors to make an easy choice, should they or a journal editor feel that their papers are ‘out of scope’ when considering other journals. The range of topics covered by Thermal Science and Engineering Progress addresses the rapid rate of development being made in thermal transfer processes as they affect traditional fields, and important growth in the topical research areas of aerospace, thermal biological and medical systems, electronics and nano-technologies, renewable energy systems, food production (including agriculture), and the need to minimise man-made thermal impacts on climate change. Review articles on appropriate topics for TSEP are encouraged, although until TSEP is fully established, these will be limited in number. Before submitting such articles, please contact one of the Editors, or a member of the Editorial Advisory Board with an outline of your proposal and your expertise in the area of your review.