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Novel hybrid thermal management system for cylindrical lithium-ion battery based on CPCM and topology-optimized liquid cooling

Author

Listed:
  • Sun, Wei
  • Li, Peng
  • Cheng, Wenmin
  • Li, Chongchong
  • Qi, Xiaolong
  • Shen, Han
  • Shao, Xiaodong

Abstract

Heat dissipation issues, particularly at high discharge rates, constrain the safe use of Li-ion batteries, making effective thermal management essential. This study proposes a novel hybrid thermal management system (BTMS) for cylindrical lithium battery packs, combining phase change cooling with microchannel liquid cooling technology. Firstly, four BTMS designs were developed using paraffin wax, composite phase change material (CPCM), conventional straight cooling plates (SCHS), and topology-optimized cooling plates (TOCHS). Numerical simulations evaluated cooling performance and energy consumption under 4C discharge. The results indicate that the TOC-BTMS, combining CPCM and TOCHS, exhibits superior thermal management, with a cell temperature 5 K lower than the SP-BTMS using paraffin wax and cold plates, and a 24.3 % reduction in phase transition fraction. Then the effects of flow rate and PCM thickness on heat transfer capability and power consumption are discussed to strike a balance between them under higher magnification (5C) discharge conditions. Finally, a delayed cooling strategy is then proposed to reduce power consumption by minimizing inefficient water flow at low system temperatures. The battery's heat generation and the system's cooling capacity determine whether liquid cooling is triggered repeatedly, causing temperature cycles. The heat transfer capacity of the cold plate and the upper limit TUL of the water-through condition influence cycle frequency. It is necessary to ensure the battery temperature remains in the cycle's low range near the end of discharge. For TOC-BTMS, a 40 mm/s flow rate, 2 mm PCM thickness, and liquid cooling conditions of [314.5 K, 316 K] are optimal. Under 4C and 5C discharge, average and maximum cell temperatures remained below 317 K and 319 K, while power consumption decreased by 44.8 % and 25.3 %. Experimental results confirmed agreement with numerical predictions.

Suggested Citation

  • Sun, Wei & Li, Peng & Cheng, Wenmin & Li, Chongchong & Qi, Xiaolong & Shen, Han & Shao, Xiaodong, 2025. "Novel hybrid thermal management system for cylindrical lithium-ion battery based on CPCM and topology-optimized liquid cooling," Energy, Elsevier, vol. 329(C).
    • Handle: RePEc:eee:energy:v:329:y:2025:i:c:s0360544225023618
    DOI: 10.1016/j.energy.2025.136719
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    References listed on IDEAS

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    1. Xu, Qiang & Xie, Yajun & Huang, Haocheng & Lin, Xue-Mei & Li, Li & Wang, Xiaochun & Zheng, Keqing, 2025. "Parametric studies and design recommendations for a novel hybrid battery thermal management system with ultrathin PCM layers between liquid cooling channels and batteries," Energy, Elsevier, vol. 337(C).
    2. Peng, Ao & Peng, Fei & Chen, Yuehao & Peng, Qi & Sun, Xiaoqin & Li, Jie, 2025. "Numerical research on baffle-enhanced liquid immersion cooling for thermal regulation in 280 Ah LiFePO4 batteries," Energy, Elsevier, vol. 336(C).

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