IDEAS home Printed from https://ideas.repec.org/a/gam/jeners/v17y2024i4p939-d1340478.html

A Novel Leak-Proof Thermal Conduction Slot Battery Thermal Management System Coupled with Phase Change Materials and Liquid-Cooling Strategies

Author

Listed:
  • Wenjun Zhang

    (School of Materials and Energy, Guangdong University of Technology, Guangzhou 510006, China)

  • Jiangyun Zhang

    (School of Materials and Energy, Guangdong University of Technology, Guangzhou 510006, China)

  • Guoqing Zhang

    (School of Materials and Energy, Guangdong University of Technology, Guangzhou 510006, China)

  • Yanxin Hu

    (School of Materials and Energy, Guangdong University of Technology, Guangzhou 510006, China)

  • Dan Shao

    (Guangdong Key Laboratory of Battery Safety, Guangzhou Institute of Energy Testing, Guangzhou 511447, China)

  • Liqin Jiang

    (Guangdong Zhuhai Supervision Testing Institute of Quality and Metrology, Zhuhai 519000, China)

  • Yuliang Wen

    (Dongguan Guixiang Insulation Material Co., Ltd., Dongguan 523861, China)

Abstract

Electric vehicles (EVs) are experiencing explosive developments due to their advantages in energy conservation and environmental protection. As a pivotal component of EVs, the safety performance of lithium-ion batteries directly affects driving miles and even safety; hence, a battery thermal management system (BTMS) is especially important. To improve the thermal safety performance of power battery modules, first, a new leak-proof phase change material (PCM)-coupled liquid-cooled composite BTMS for large-scale battery modules is proposed in this research. Second, the numerical simulation analysis method was utilized to analyze the influences of the fluid flow channel shape, working fluid inlet temperature, inlet velocity, and reverse flow conditions on the BTMS. Eventually, the abovementioned performances were compared with the traditional PCM-coupled liquid-cooling strategy. The relative data indicated that the T max was reduced by 17.5% and the ΔT max was decreased by 19.5% compared to the liquid-cooling approach. Further, compared with conventionally designed PCM composite liquid cooling, the ΔT max was reduced by 34.9%. The corresponding data showed that, when using the e-type flow channel, reverse flow II, the inlet flow velocity was 0.001–0.005 m/s, and the inlet temperature was the ambient temperature of the working condition. The thermal performance of the anti-leakage system with a thermal conduction slot PCM-coupled liquid-cooling composite BTMS reached optimal thermal performance. The outcome proved the superiority of the proposed BTMS regarding temperature control and temperature equalization capabilities. It also further reduced the demand for liquid-cooling components, avoided the problem of the easy leakage of the PCM, and decreased energy consumption.

Suggested Citation

  • Wenjun Zhang & Jiangyun Zhang & Guoqing Zhang & Yanxin Hu & Dan Shao & Liqin Jiang & Yuliang Wen, 2024. "A Novel Leak-Proof Thermal Conduction Slot Battery Thermal Management System Coupled with Phase Change Materials and Liquid-Cooling Strategies," Energies, MDPI, vol. 17(4), pages 1-24, February.
    • Handle: RePEc:gam:jeners:v:17:y:2024:i:4:p:939-:d:1340478
    as

    Download full text from publisher

    File URL: https://www.mdpi.com/1996-1073/17/4/939/pdf
    Download Restriction: no
    File URL: https://www.mdpi.com/1996-1073/17/4/939/
    Download Restriction: no
    ---><---

    References listed on IDEAS

    as
    1. Zhang, Wencan & Huang, Liansheng & Zhang, Zhongbo & Li, Xingyao & Ma, Ruixin & Ren, Yimao & Wu, Weixiong, 2022. "Non-uniform phase change material strategy for directional mitigation of battery thermal runaway propagation," Renewable Energy, Elsevier, vol. 200(C), pages 1338-1351.
    2. 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).
    3. Dan Dan & Yihang Zhao & Mingshan Wei & Xuehui Wang, 2023. "Review of Thermal Management Technology for Electric Vehicles," Energies, MDPI, vol. 16(12), pages 1-38, June.
    4. Anisha & Anil Kumar, 2023. "Identification and Mitigation of Shortcomings in Direct and Indirect Liquid Cooling-Based Battery Thermal Management System," Energies, MDPI, vol. 16(9), pages 1-21, April.
    5. Kalina Detka & Krzysztof Górecki, 2023. "Selected Technologies of Electrochemical Energy Storage—A Review," Energies, MDPI, vol. 16(13), pages 1-36, June.
    Full references (including those not matched with items on IDEAS)

    Citations

    Citations are extracted by the CitEc Project, subscribe to its RSS feed for this item.
    as


    Cited by:

    1. 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).

    Most related items

    These are the items that most often cite the same works as this one and are cited by the same works as this one.
    1. Lipeng Xu & Chongwang Tian & Chunjiang Bao & Jinsheng Zhao & Xuning Leng, 2023. "Improving the Electrochemical Performance of Core–Shell LiNi 0.8 Co 0.1 Mn 0.1 O 2 Cathode Materials Using Environmentally Friendly Phase Structure Control Process," Energies, MDPI, vol. 16(10), pages 1-17, May.
    2. Anne Christine Lusk & Xin Li & Qiming Liu, 2023. "If the Government Pays for Full Home-Charger Installation, Would Affordable-Housing and Middle-Income Residents Buy Electric Vehicles?," Sustainability, MDPI, vol. 15(5), pages 1-26, March.
    3. Liu, Xun & Wu, Pan-Yun & Su, Chu-qi & Xiong, Xin & Wang, Xiang-Yi & Wang, Yi-Ping, 2025. "Research on precise temperature control performance of battery thermal management system integrating piezoelectric pump and thermoelectric cooler," Energy, Elsevier, vol. 317(C).
    4. Li, Jiaqi & Fan, Guodong & Zhang, Xi, 2025. "Hybrid end-to-end battery modeling and SOH estimation via physics-data fusion and maximum mean discrepancy minimization," Energy, Elsevier, vol. 340(C).
    5. Zhang, Zhen & Zhu, Yuhao & Gong, Yichang & Wang, Teng & Cui, Naxin & Shang, Yunlong, 2025. "Insight into the whole from the part: Redefined state of health for lithium-ion batteries based on optimal charging fragment search," Energy, Elsevier, vol. 320(C).
    6. Lei, Deyong & Wang, Yun & Fu, Jingfei & Zhu, Xiaobao & Shi, Jing & Wang, Yachao, 2024. "Electrochemical-thermal analysis of large-sized lithium-ion batteries: Influence of cell thickness and cooling strategy in charging," Energy, Elsevier, vol. 307(C).
    7. Wu, Chunxia & Sun, Yalong & Tang, Heng & Zhang, Shiwei & Yuan, Wei & Zhu, Likuan & Tang, Yong, 2024. "A review on the liquid cooling thermal management system of lithium-ion batteries," Applied Energy, Elsevier, vol. 375(C).
    8. 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).
    9. Maryam Ghalkhani & Saeid Habibi, 2022. "Review of the Li-Ion Battery, Thermal Management, and AI-Based Battery Management System for EV Application," Energies, MDPI, vol. 16(1), pages 1-16, December.
    10. Li, Heng & Liu, Zhijun & Bin Kaleem, Muaaz & Duan, Lijun & Ruan, Siqi & Liu, Weirong, 2025. "Fault detection for lithium-ion batteries of electric vehicles with spatio-temporal autoencoder," Applied Energy, Elsevier, vol. 392(C).
    11. Chen, Mingyi & Yu, Yue & Ouyang, Dongxu & Weng, Jingwen & Zhao, Luyao & Wang, Jian & Chen, Yin, 2024. "Research progress of enhancing battery safety with phase change materials," Renewable and Sustainable Energy Reviews, Elsevier, vol. 189(PA).
    12. Wu, Jiafeng & Li, Lin & Yin, Zichao & Li, Zhe & Wang, Tong & Tan, Yunfeng & Tan, Dapeng, 2024. "Mass transfer mechanism of multiphase shear flows and interphase optimization solving method," Energy, Elsevier, vol. 292(C).
    13. Zhuang, Zixian & Gu, Sijie & Luan, Weiling & Li, Jun & Chen, Haofeng, 2025. "A record fast ACP self-heating for lithium-ion batteries without capacity loss based on electrochemical-thermal coupling model," Applied Energy, Elsevier, vol. 393(C).
    14. Huang, Jianbai & Dong, Xuesong & Chen, Jinyu & Zeng, Anqi, 2023. "The slow-release effect of recycling on rapid demand growth of critical metals from EV batteries up to 2050: Evidence from China," Resources Policy, Elsevier, vol. 82(C).
    15. Wudil, Yakubu Sani & Gondal, M.A. & Al-Osta, Mohammed A., 2025. "Designing fire-retardant polymer-based electrolytes and separators for high-energy-density lithium-ion batteries via combustion calorimetry and machine learning," Energy, Elsevier, vol. 335(C).
    16. Li, Li & Ling, Lei & Xie, Yajun & Zhou, Wencai & Wang, Tianbo & Zhang, Lanchun & Bei, Shaoyi & Zheng, Keqing & Xu, Qiang, 2023. "Comparative study of thermal management systems with different cooling structures for cylindrical battery modules: Side-cooling vs. terminal-cooling," Energy, Elsevier, vol. 274(C).
    17. Arti Aniqa Tabassum & Haeng Muk Cho & Md. Iqbal Mahmud, 2024. "Essential Features and Torque Minimization Techniques for Brushless Direct Current Motor Controllers in Electric Vehicles," Energies, MDPI, vol. 17(18), pages 1-27, September.
    18. Wei, Meng & Balaya, Palani & Ye, Min & Song, Ziyou, 2022. "Remaining useful life prediction for 18650 sodium-ion batteries based on incremental capacity analysis," Energy, Elsevier, vol. 261(PA).
    19. Tian, Aina & He, Luyao & Ding, Tao & Dong, Kailang & Wang, Yuqin & Jiang, Jiuchun, 2025. "A generic physics-informed neural network framework for lithium-ion batteries state of health estimation," Energy, Elsevier, vol. 332(C).
    20. Sergi Obrador Rey & Juan Alberto Romero & Lluis Trilla Romero & Àlber Filbà Martínez & Xavier Sanchez Roger & Muhammad Attique Qamar & José Luis Domínguez-García & Levon Gevorkov, 2023. "Powering the Future: A Comprehensive Review of Battery Energy Storage Systems," Energies, MDPI, vol. 16(17), pages 1-21, September.

    More about this item

    Keywords

    ;
    ;
    ;
    ;
    ;

    Statistics

    Access and download statistics

    Corrections

    All material on this site has been provided by the respective publishers and authors. You can help correct errors and omissions. When requesting a correction, please mention this item's handle: RePEc:gam:jeners:v:17:y:2024:i:4:p:939-:d:1340478. See general information about how to correct material in RePEc.

    If you have authored this item and are not yet registered with RePEc, we encourage you to do it here. This allows to link your profile to this item. It also allows you to accept potential citations to this item that we are uncertain about.

    If CitEc recognized a bibliographic reference but did not link an item in RePEc to it, you can help with this form .

    If you know of missing items citing this one, you can help us creating those links by adding the relevant references in the same way as above, for each refering item. If you are a registered author of this item, you may also want to check the "citations" tab in your RePEc Author Service profile, as there may be some citations waiting for confirmation.

    For technical questions regarding this item, or to correct its authors, title, abstract, bibliographic or download information, contact: MDPI Indexing Manager (email available below). General contact details of provider: https://www.mdpi.com .

    Please note that corrections may take a couple of weeks to filter through the various RePEc services.

    IDEAS is a RePEc service. RePEc uses bibliographic data supplied by the respective publishers.