IDEAS home Printed from https://ideas.repec.org/a/eee/energy/v330y2025ics0360544225025149.html

Tubeless shape-stabilized phase change materials channels for all-climate battery thermal management

Author

Listed:
  • Xu, Xinyue
  • Li, Peihang
  • Weng, Keyu
  • Zheng, Pengjun
  • Feng, Yufan
  • Liu, Da
  • Hu, ShengXin
  • Qu, Weiping
  • Shao, Jin
  • Zou, Deqiu

Abstract

As power batteries are widely used, the need for efficient thermal management is increasing. Combining multiple cooling methods is a trend, but it raises costs and weight. Developing a battery thermal management system (BTMS) suitable for different climates is essential. This paper proposes an all-climate BTMS using dual-function shape-stabilized phase change material (SSPCM) channels coupled with graphene oxide (GO) emulsion. The innovative SSPCM channel, with high thermal (21.21 W m−1 K−1) and electrical (456.49 S/m) conductivity, allows direct coupling with liquid cooling, enabling both cooling and preheating of the battery. The GO emulsion enhances thermal conductivity by 36.96 % and reduces supercooling by 11.39 °C compared to pure phase change emulsion (PCE). The proposed BTMS, using SSPCM channels, shows better thermal management performance compared to the GO emulsion/Metal channel system, reducing the maximum temperature (Tmax) by 5.4 °C and the temperature difference (ΔTmax) by 1.9 °C. The system's preheating rate is 3.05 °C/min, and the ΔTmax under various conditions is below 5 °C. This approach, combining SSPCM with phase change emulsion, offers a promising solution for power battery thermal management.

Suggested Citation

  • Xu, Xinyue & Li, Peihang & Weng, Keyu & Zheng, Pengjun & Feng, Yufan & Liu, Da & Hu, ShengXin & Qu, Weiping & Shao, Jin & Zou, Deqiu, 2025. "Tubeless shape-stabilized phase change materials channels for all-climate battery thermal management," Energy, Elsevier, vol. 330(C).
    • Handle: RePEc:eee:energy:v:330:y:2025:i:c:s0360544225025149
    DOI: 10.1016/j.energy.2025.136872
    as

    Download full text from publisher

    File URL: http://www.sciencedirect.com/science/article/pii/S0360544225025149
    Download Restriction: Full text for ScienceDirect subscribers only
    File URL: https://libkey.io/10.1016/j.energy.2025.136872?utm_source=ideas
    LibKey link: if access is restricted and if your library uses this service, LibKey will redirect you to where you can use your library subscription to access this item
    ---><---

    As the access to this document is restricted, you may want to

    for a different version of it.

    References listed on IDEAS

    as
    1. Luo, Ding & Wu, Zihao & Jiang, Li & Yan, Yuying & Chen, Wei-Hsin & Cao, Jin & Cao, Bingyang, 2024. "Realizing rapid cooling and latent heat recovery in the thermoelectric-based battery thermal management system at high temperatures," Applied Energy, Elsevier, vol. 370(C).
    2. Lee, Seunghoon & Lee, Hyoseong & Jun, Yong Joo & Lee, Hoseong, 2024. "Hybrid battery thermal management system coupled with paraffin/copper foam composite phase change material," Applied Energy, Elsevier, vol. 353(PA).
    3. Zhang, Weitao & Sun, Qichao & Zhou, Xin & Wu, Lianying & Hu, Yangdong, 2024. "Investigation on the thermal behavior of thermal management system for battery pack with heat pipe based on multiphysics coupling model," Energy, Elsevier, vol. 308(C).
    4. Jiang, Le & Zhang, Hengyun & Li, Junwei & Xia, Peng, 2019. "Thermal performance of a cylindrical battery module impregnated with PCM composite based on thermoelectric cooling," Energy, Elsevier, vol. 188(C).
    5. Wei Wei & Sankaran Ramakrishnan & Zachary A. Needell & Jessika E. Trancik, 2021. "Personal vehicle electrification and charging solutions for high-energy days," Nature Energy, Nature, vol. 6(1), pages 105-114, January.
    6. Mo, Chongmao & Xie, Jiekai & Zhang, Guoqing & Zou, Zhiyang & Yang, Xiaoqing, 2024. "All-climate battery thermal management system integrating units-assembled phase change material module with forced air convection," Energy, Elsevier, vol. 294(C).
    7. Tao Zhu & Haitao Min & Yuanbin Yu & Zhongmin Zhao & Tao Xu & Yang Chen & Xinyong Li & Cong Zhang, 2017. "An Optimized Energy Management Strategy for Preheating Vehicle-Mounted Li-ion Batteries at Subzero Temperatures," Energies, MDPI, vol. 10(2), pages 1-23, February.
    8. Li, Zhi & Lu, Yiji & Huang, Rui & Chang, Jinwei & Yu, Xiaonan & Jiang, Ruicheng & Yu, Xiaoli & Roskilly, Anthony Paul, 2021. "Applications and technological challenges for heat recovery, storage and utilisation with latent thermal energy storage," Applied Energy, Elsevier, vol. 283(C).
    9. Yangying Zhu & Jin Xie & Allen Pei & Bofei Liu & Yecun Wu & Dingchang Lin & Jun Li & Hansen Wang & Hao Chen & Jinwei Xu & Ankun Yang & Chun-Lan Wu & Hongxia Wang & Wei Chen & Yi Cui, 2019. "Fast lithium growth and short circuit induced by localized-temperature hotspots in lithium batteries," Nature Communications, Nature, vol. 10(1), pages 1-7, December.
    10. T. M. M. Heenan & I. Mombrini & A. Llewellyn & S. Checchia & C. Tan & M. J. Johnson & A. Jnawali & G. Garbarino & R. Jervis & D. J. L. Brett & M. Michiel & P. R. Shearing, 2023. "Mapping internal temperatures during high-rate battery applications," Nature, Nature, vol. 617(7961), pages 507-512, May.
    11. Wu, Chunxia & Sun, Yalong & Tang, Heng & Zhang, Shiwei & Yuan, Wei & Zhu, Likuan & Tang, Yong, 2024. "A review on the liquid cooling thermal management system of lithium-ion batteries," Applied Energy, Elsevier, vol. 375(C).
    12. Gu, Heng & Chang, Yunwei & Chen, Yuanyuan & Guo, Jiang rong & Zou, Deqiu, 2024. "Experimental research on pipeless power battery cooling system using shape-stabilized phase change materials (SSPCM) coupled with seawater," Energy, Elsevier, vol. 286(C).
    13. Ryan S. Longchamps & Shanhai Ge & Zachary J. Trdinich & Jie Liao & Chao-Yang Wang, 2024. "Battery electronification: intracell actuation and thermal management," Nature Communications, Nature, vol. 15(1), pages 1-11, December.
    14. Chen, Chengzhi & Qian, Yangjie & Xu, Guiling & Zhang, Qi & Lu, Ping, 2024. "Numerical investigation on thermal management performance of soft packing Li-ion batteries with oblique multi-channel cold plates," Renewable Energy, Elsevier, vol. 234(C).
    15. Li, Jintao & E, Jiaqiang & Ding, Jiangjun & Cai, Lei & Luo, Bo, 2024. "Effect analysis on the low-temperature preheating performance of a novel micro-combustor air preheater for the cold start of the Li-ion battery packs," Energy, Elsevier, vol. 312(C).
    Full references (including those not matched with items on IDEAS)

    Most related items

    These are the items that most often cite the same works as this one and are cited by the same works as this one.
    1. Luo, Ding & Jiang, Li & Chen, Hao & Ma, Yanlei & Zhang, Peng & Chen, Zhanming & Geng, Limin, 2025. "Enhanced energy efficiency and thermal performance of a hybrid battery thermal management system by a delay control strategy of thermoelectric coolers," Renewable Energy, Elsevier, vol. 253(C).
    2. Suresh, C. & Awasthi, Abhishek & Kumar, Binit & Im, Seong-kyun & Jeon, Yongseok, 2025. "Advances in battery thermal management for electric vehicles: A comprehensive review of hybrid PCM-metal foam and immersion cooling technologies," Renewable and Sustainable Energy Reviews, Elsevier, vol. 208(C).
    3. Luo, Ding & Wu, Zihao & Zhang, Ziye & Chen, Hao & Geng, Limin & Ji, Zhenhua & Zhang, Wenbo & Zhang, Peng, 2025. "Transient thermal analysis of a thermoelectric-based battery thermal management system at high temperatures," Energy, Elsevier, vol. 318(C).
    4. Wang, Zhangzhou & He, Yurong & Tang, Tianqi & Cheng, Gong, 2025. "Optimized thermal management and safety assurance with flame-retardant phase change materials for lithium-ion batteries," Energy, Elsevier, vol. 335(C).
    5. Fang, Xinrui & Tian, Haonan & Wu, Muyao & Qiu, Yangrui & Li, Heng & Wang, Li, 2025. "A real-time feedback and adaptive control strategy for battery thermal management system," Energy, Elsevier, vol. 333(C).
    6. Wang, Libiao & Zuo, Hongyan & Zhang, Bin & Jia, Guohai, 2025. "Effects of supercritical carbon dioxide cooling on heat dissipation performance enhancement of a prismatic LiFePO4 battery pack," Energy, Elsevier, vol. 314(C).
    7. Luo, Ding & Wu, Zihao & Jiang, Li & Yan, Yuying & Chen, Wei-Hsin & Cao, Jin & Cao, Bingyang, 2024. "Realizing rapid cooling and latent heat recovery in the thermoelectric-based battery thermal management system at high temperatures," Applied Energy, Elsevier, vol. 370(C).
    8. Cai, Yunxiang & Sun, Qin & Gu, Xiaobin & Li, Yuping & Luo, Weimin & Zhang, Yanjun & Zhang, Bobo & Huang, Gongsheng & Dong, Kaijun, 2024. "Multi-objective optimization of battery thermal management system based on a novel embedded hybrid cooling plate considering time-based early shutdown strategy," Energy, Elsevier, vol. 312(C).
    9. Manisha, & Tiwari, Sumit & Sahdev, Ravinder Kumar & Chhabra, Deepak & Kumari, Meena & Ali, Arshad & Sehrawat, Ravin & Tiwari, Prabhakar, 2025. "Advancements and challenges in battery thermal management for electric vehicles," Renewable and Sustainable Energy Reviews, Elsevier, vol. 209(C).
    10. Najmi, Aezid-Ul-Hassan & Wahab, Abdul & Prakash, Rohith & Schopen, Oliver & Esch, Thomas & Shabani, Bahman, 2025. "Thermal management of fuel cell-battery electric vehicles: Challenges and solutions," Applied Energy, Elsevier, vol. 387(C).
    11. Yi Zhang & Haoran Yu & Yingzhen Hou & Neng Zhu, 2025. "Multi-Objective Optimization Research Based on NSGA-II and Experimental Study of Triplex-Tube Phase Change Thermal Energy Storage System," Energies, MDPI, vol. 18(8), pages 1-27, April.
    12. Beata Pytlik & Daniel Smykowski & Piotr Szulc, 2022. "The Impact of Baffle Geometry in the PCM Heat Storage Unit on the Charging Process with High and Low Water Streams," Energies, MDPI, vol. 15(24), pages 1-17, December.
    13. Wang, Yuan & Wang, Yutao & He, Tianbiao & Mao, Ning, 2024. "A numerical study on a hybrid battery thermal management system based on PCM and wavy microchannel liquid cooling," Renewable Energy, Elsevier, vol. 235(C).
    14. Elsewify, O. & Souri, M. & Esfahani, M.N. & Hosseinzadeh, E. & Jabbari, M., 2021. "A new method for internal cooling of a large format lithium-ion battery pouch cell," Energy, Elsevier, vol. 225(C).
    15. Luo, Ding & Yang, Shuo & Zhang, Haokang & Cao, Jin & Yan, Yuying & Chen, Hao, 2025. "Performance improvement of an automotive thermoelectric generator by introducing a novel split fin structure," Applied Energy, Elsevier, vol. 382(C).
    16. Fan, Zhaohui & Fu, Yijie & Liang, Hong & Gao, Renjing & Liu, Shutian, 2023. "A module-level charging optimization method of lithium-ion battery considering temperature gradient effect of liquid cooling and charging time," Energy, Elsevier, vol. 265(C).
    17. Zhou, Zhizuan & Wang, Dong & Peng, Yang & Li, Maoyu & Wang, Boxuan & Cao, Bei & Yang, Lizhong, 2022. "Experimental study on the thermal management performance of phase change material module for the large format prismatic lithium-ion battery," Energy, Elsevier, vol. 238(PC).
    18. Dhamodharan, Palanisamy & Manalac, Ed Joshua & Prabakaran, Rajendran & Kim, Sung Chul, 2025. "Hybrid modeling of two-phase refrigerant cooling integrated with EV heat pumps for Li-ion batteries under high discharge rates," Energy, Elsevier, vol. 333(C).
    19. Chen, Jie & Wang, Ruochen & Ding, Renkai & Luo, Ding, 2024. "Comprehensive comparison and applicable range of separating and coupling numerical models of thermoelectric generation device for waste heat recovery," Energy, Elsevier, vol. 304(C).
    20. Bhattacharyya, Sankhadeep & Dinh, Quang Truong & McGordon, Andrew, 2025. "Optimising thermoelectric coolers for battery thermal management in light electric vehicles," Applied Energy, Elsevier, vol. 386(C).

    More about this item

    Keywords

    ;
    ;
    ;
    ;
    ;

    Statistics

    Access and download statistics

    Corrections

    All material on this site has been provided by the respective publishers and authors. You can help correct errors and omissions. When requesting a correction, please mention this item's handle: RePEc:eee:energy:v:330:y:2025:i:c:s0360544225025149. See general information about how to correct material in RePEc.

    If you have authored this item and are not yet registered with RePEc, we encourage you to do it here. This allows to link your profile to this item. It also allows you to accept potential citations to this item that we are uncertain about.

    If CitEc recognized a bibliographic reference but did not link an item in RePEc to it, you can help with this form .

    If you know of missing items citing this one, you can help us creating those links by adding the relevant references in the same way as above, for each refering item. If you are a registered author of this item, you may also want to check the "citations" tab in your RePEc Author Service profile, as there may be some citations waiting for confirmation.

    For technical questions regarding this item, or to correct its authors, title, abstract, bibliographic or download information, contact: Catherine Liu (email available below). General contact details of provider: http://www.journals.elsevier.com/energy .

    Please note that corrections may take a couple of weeks to filter through the various RePEc services.

    IDEAS is a RePEc service. RePEc uses bibliographic data supplied by the respective publishers.