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Design and optimization of a thermoelectric hybrid battery thermal management system with improved heat transfer for high-rate discharge conditions

Author

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  • Luo, Ding
  • Li, Mingyu
  • Chen, Hao
  • Zhang, Peng

Abstract

This study presents a novel battery thermal management system (BTMS) integrating phase change material (PCM), liquid cooling, and thermoelectric coolers (TECs) to maintain a stable working environment for batteries. To address the deficiency in optimizing hybrid battery thermal management system for PCM thermal saturation under high discharge rates, a new fin structure is proposed to enhance heat transfer between the TEC, battery, and PCM. The thermal performance of the proposed BTMS is evaluated using a transient thermo-electro-fluid multi-physics numerical model. The results indicate that increasing the TEC input current, fin length, and coolant flow rate can reduce the maximum temperature and the PCM liquid fraction of the battery pack. Optimizing the fin length in the middle region improves temperature uniformity and reduces the temperature difference. However, the coolant flow rate and TEC input current have a minimal effect on the temperature difference. Based on numerical simulations, the optimal fin length combination is found to be 5 mm for the outer fin and 5.4 mm for the central fin. Under these conditions, with a TEC input current of 1.6 A and a liquid cooling plate flow rate of 0.08 m/s, the maximum temperature, temperature difference, and PCM liquid fraction of the battery pack are controlled at 321.92 K, 3.49 K, and 0.179, respectively. These findings provide valuable insights and technical references for the optimal design of the BTMS.

Suggested Citation

  • Luo, Ding & Li, Mingyu & Chen, Hao & Zhang, Peng, 2026. "Design and optimization of a thermoelectric hybrid battery thermal management system with improved heat transfer for high-rate discharge conditions," Renewable Energy, Elsevier, vol. 256(PI).
    • Handle: RePEc:eee:renene:v:256:y:2026:i:pi:s0960148125023857
    DOI: 10.1016/j.renene.2025.124721
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