Multi-objective optimization of a hybrid battery thermal management system coupling topology-optimized liquid cooling with PCM-honeycomb scaffolds

To mitigate excessive temperature rise and thermal non-uniformity in high-capacity batteries, this study proposes a novel hybrid battery thermal management system integrating topology-optimized liquid cooling with a phase change material infiltrated bionic honeycomb scaffold. 3D numerical simulations are conducted to evaluate the system thermohydraulic performance under varying topology optimization weights. To resolve inherent conflicts among performance indicators, a multi-objective optimization algorithm is employed following a comprehensive parameter sensitivity analysis. Results demonstrate that the hybrid thermal management system significantly outperforms standalone liquid cooling, reducing maximum temperature by 1.86 °C (to 30.85 °C) and maximum temperature difference by 28.10% (to 4.81 °C). Under the global optimal configuration, the temperature difference further converges to 4.76 °C, with a minimal pressure drop of 14.74 Pa and an 89% liquid fraction. Ultimately, this design achieves superior thermal regulation, efficient latent heat utilization, and minimized parasitic pump power, providing a robust reference for future high-efficiency battery thermal management system optimization.