Passive and hybrid battery thermal management system by cooling flow control, employing nano-PCM, fins, and metal foam

The performance and safety of lithium-ion batteries, especially in electric and hybrid vehicles, rely on efficient thermal management. Thus, researchers have shown interest in investigating passive, active, and hybrid approaches for battery thermal management (BTM). This study presents a novel hybrid design for a BTM system involving three cylindrical 18650 batteries encased in phase change material (PCM). The research evaluates the impact of fluid flow velocity and direction in the channels on battery temperature, seeking temperature reduction and uniformity. To optimize the proposed system performance, three methods for improving heat transfer in the PCM have been explored and compared, including using nanoparticles (3 %–9 % volume percentage), employing fins (2 and 4 fins), and implementing metal foam (porosity ranging from 85 % to 95 %). Results indicate that, for a 4C discharge rate, incorporating 9 % nanoparticles and 4 fins in the hybrid mode reduces peak temperature by 5.18 and 10.36 K, respectively, compared to the hybrid modes without nanoparticles and fins. These reductions are 10.41 and 9.20 K superior to the corresponding passive modes diminutions, respectively. Additionally, using copper foam with 90 % porosity reduces battery peak temperature by 12.57 K at a 3C discharge rate, highlighting the effectiveness of this method.