Research and optimization of configurable modular thermal management system for multi-ambient temperatures

It is crucial to keep the temperature of lithium-ion batteries within a reasonable range. This study presents a configurable modular thermal management system that integrates freely configurable active and passive thermal management modules to meet diverse application demands. A bio-based phase change material (PCM) with a phase transition temperature of 40.1°C was developed for a passive thermal management module. A model of battery thermal management was developed to assess the impacts of PCM geometry and active thermal management parameters on battery pack temperatures. Building on this, the real-world applicability of the thermal management system was evaluated across diverse cities, leading to optimized solutions tailored to each city. The results indicate that increasing the PCM height enhances cooling capacity by 26%, but extends heating time by 75% compared to increasing its width. Raising the heating temperature from 35°C to 45°C shortens heating time by 45%, but increases energy consumption by 49%. High-temperature cities require more active thermal management modules, maintaining battery pack temperature less than 45°C at a 42°C ambient temperature. Temperate cities maximize passive module integration, achieving a battery pack temperature of less than 45°C at a 38°C ambient temperature without energy consumption. Low-temperature cities utilize heating plate substitution for an active thermal management module, yielding 10% energy savings. This research provides a reference basis for the direct selection and application of the configurable modular thermal management system in diverse scenarios.