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Effect of battery surface microtopography on immersion boiling thermal management for lithium-ion batteries

Author

Listed:
  • Lyu, Peizhao
  • Xiao, Yunlong
  • Fan, Xianglong
  • Han, Jie
  • Liu, Xinjian
  • Rao, Zhonghao

Abstract

Thermal runaway (TR) of lithium-ion batteries is the main issue that causes fire accidents in electric vehicles (EVs) and energy storage systems (EESs). Battery thermal management (BTM) plays an important role in preventing TR and prolonging the lifespan of the battery. Immersion boiling thermal management (IBTM) technology demonstrates superior control over the temperature characteristics of lithium-ion batteries due to its exceptional heat dissipation ability. This study focused on the effect of battery surface microtopography (i.e., battery with cover/plastic film, BwC, and without cover, BwoC) on BTM performance by laser-microscopy. The experimental results demonstrate that the charge/discharge temperature differences of BwoC are 2.89 °C and 2.67 °C, respectively, lower than those of the BwC (4.13 °C and 3.05 °C) during the IBTM process. The analysis of over 20 samples from the battery surface revealed that the maximum values of surface roughness (Sa) and height difference (Sz) for BwoC are 91.98 μm and 906.04 μm, respectively, while the maximum values of Sa and Sz for BwC are 56.63 μm and 379.94 μm, respectively, which means that the surface boiling characteristics of BwoC are superior to those of BwC, and enhance IBTM performance. This study holds significant importance in facilitating the development and application of IBTM. It also plays a crucial role in elevating the safety performance of EVs and EESs.

Suggested Citation

  • Lyu, Peizhao & Xiao, Yunlong & Fan, Xianglong & Han, Jie & Liu, Xinjian & Rao, Zhonghao, 2026. "Effect of battery surface microtopography on immersion boiling thermal management for lithium-ion batteries," Renewable Energy, Elsevier, vol. 256(PD).
    • Handle: RePEc:eee:renene:v:256:y:2026:i:pd:s0960148125019226
    DOI: 10.1016/j.renene.2025.124258
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    References listed on IDEAS

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