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A numerical study on a hybrid battery thermal management system based on PCM and wavy microchannel liquid cooling

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  • Wang, Yuan
  • Wang, Yutao
  • He, Tianbiao
  • Mao, Ning

Abstract

With the emerging development of electrical vehicle, the efficient thermal management of the lithium-ion battery is becoming a critical point for its wide application and normal operating. Hence, based on the advantages of liquid cooling and PCM, a novel hybrid cooling system using PCM coupled with wavy microchannel cooling plate (PCM-WMCP) was proposed in this paper, and a numerical study was carried out to investigate its performance. It's found the hybrid cooling system with PCM and microchannel cooling plate showed much lower battery temperature than individual PCM and air cooling systems, moreover, among the hybrid cooling systems, the novel PCM-WMCP exhibited 2 K lower maximum battery temperature than PCM-SMCP (straight microchannel cooling plate) type at 1C, and increased potential in utilizing PCM for heat dissipation. The PCM was further modified to composite PCM (CPCM) by adding expanded graphite, which was found to realize a further lower maximum battery temperature and more uniform battery temperature field, with graphite mass fraction of 10 %. Besides, facing thermal runaway, the CPCM-WMCP cooling system showed a better temperature control ability compared to CPCM-SMCP, with temperature suppressed to below 318 K, and the maximum temperature difference at about 1.6 K.

Suggested Citation

  • 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).
    • Handle: RePEc:eee:renene:v:235:y:2024:i:c:s0960148124013417
    DOI: 10.1016/j.renene.2024.121273
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    References listed on IDEAS

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    5. Rezazadeh, Rasoul & Rostami, Javad & Qaderi, Alireza, 2025. "Numerical investigation of Conjugate heat transfer in micro-electronic devices using wavy microchannels with nanofluid in the presence of porous ribs," Energy, Elsevier, vol. 338(C).
    6. Su Woong Hyun & Jae Hyuk Kim & Dong Ho Shin, 2025. "Hybrid PCM–Liquid Cooling System with Optimized Channel Design for Enhanced Thermal Management of Lithium–Ion Batteries," Energies, MDPI, vol. 18(18), pages 1-22, September.
    7. Liu, Jiahao & Tao, Liyanyu & Yang, Qinyuan & Wang, Jinhui, 2026. "Recent advances in immersion cooling for thermal management of lithium-ion batteries," Renewable and Sustainable Energy Reviews, Elsevier, vol. 226(PE).
    8. Saxena, Vivek & Sahu, Santosh K. & Kundalwal, Shailesh I. & Tsai, Peichun Amy, 2025. "Enhanced thermal management system for Li-ion batteries using phase change material and liquid cooling under realistic driving cycles," Energy, Elsevier, vol. 318(C).
    9. Fan, Yiwei & Wang, Zhaohui & Yang, Haonan & Yang, Wen & He, Ping & Zhang, Xiaofeng, 2025. "Performance analysis and optimized design of hybrid battery thermal management system integrating leak-free PCM with liquid cooling under extreme temperature conditions," Energy, Elsevier, vol. 341(C).

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