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Thermal performance analysis of a new type of branch-fin enhanced battery thermal management PCM module

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  • Zhang, Furen
  • Lu, Fu
  • Liang, Beibei
  • Zhu, Yilin
  • Gou, Huan
  • Xiao, Kang
  • He, Yanxiao

Abstract

To solve the problem of the lightweight design of metal fins and strengthen the heat transfer between phase change material (PCM) and lithium batteries, the synergistic design of fins and phase change material-battery thermal management system (PCM-BTMS) is particularly important. In this paper, 9 new branch fin design schemes were proposed based on the conventional straight fin. The reliability of the computational fluid dynamics model was verified through the heat transfer experiments at different discharge rates. Firstly, the thermal performances of 9 new fins and the conventional straight fin under 5C discharge rate were compared and analyzed, and the optimal model was selected. Secondly, the effects of transverse fin coverage area, number, arc length, thickness, and arc length of inner and outer arc fins on the thermal performance were analyzed considering the effects of different heat transfer coefficients. The results show that the preferred fins have less effect on the heat transfer coefficient enhanced thermal performance compared with the conventional fins; the average cell temperature is reduced by 3.14 K and 3.92 K respectively by increasing the fin coverage area and the number of transverse fins to increase the contact area with PCM to enhance heat dissipation; the average cell temperature changes more significantly with the inner arc fins, and the cell temperature of Case H6 was reduced by 7.2 K; while the transverse fin arc length extension reduced the thermal performance of the system in high temperature cases. The volume of system remained the same, and the thickness of the transverse fins decreased the heat storage capacity of the system when the thickness of the transverse fins was larger. The optimal fins could keep the average cell temperature within 318.15 K. The heat transfer capability was improved by 14.98%, the operating time was extended by 131.5%, and the system weight was reduced by 10.28%.

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  • Zhang, Furen & Lu, Fu & Liang, Beibei & Zhu, Yilin & Gou, Huan & Xiao, Kang & He, Yanxiao, 2023. "Thermal performance analysis of a new type of branch-fin enhanced battery thermal management PCM module," Renewable Energy, Elsevier, vol. 206(C), pages 1049-1063.
    • Handle: RePEc:eee:renene:v:206:y:2023:i:c:p:1049-1063
    DOI: 10.1016/j.renene.2023.02.083
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    References listed on IDEAS

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    1. Zhang, Xinghui & Li, Zhao & Luo, Lingai & Fan, Yilin & Du, Zhengyu, 2022. "A review on thermal management of lithium-ion batteries for electric vehicles," Energy, Elsevier, vol. 238(PA).
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    Cited by:

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    3. Zheng, Aodi & Gao, Huan & Jia, Xiongjie & Cai, Yuhao & Yang, Xiaohu & Zhu, Qiang & Jiang, Haoran, 2024. "Deep learning-assisted design for battery liquid cooling plate with bionic leaf structure considering non-uniform heat generation," Applied Energy, Elsevier, vol. 373(C).
    4. Wang, Chuang & Liu, Qixing & Wang, Zhiqiang & Cheng, Xingxing, 2025. "A review of power battery cooling technologies," Renewable and Sustainable Energy Reviews, Elsevier, vol. 213(C).
    5. An, Zhiguo & Liu, Huaixi & Gao, Weilin & Zhang, Jianping, 2024. "A triple-hybrid battery thermal management system with drop-shaped fin channels for improving weather tolerance," Energy, Elsevier, vol. 307(C).
    6. 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).
    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. Zhang, Liwei & Shang, Bichen & Sun, Weijie & Tao, Yao & Li, Xueren & Tu, Jiyuan, 2024. "Data-driven optimization of nano-PCM arrangements for battery thermal management based on Lattice Boltzmann simulation," Energy, Elsevier, vol. 313(C).
    9. Chen-Lung Wang & Jik Chang Leong, 2024. "Analysis of Thermal Management Strategies for 21700 Lithium-Ion Batteries Incorporating Phase Change Materials and Porous Copper Foam with Different Battery Orientations," Energies, MDPI, vol. 17(7), pages 1-27, March.

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