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Analysis of Thermal Management Strategies for 21700 Lithium-Ion Batteries Incorporating Phase Change Materials and Porous Copper Foam with Different Battery Orientations

Author

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  • Chen-Lung Wang

    (Department of Vehicle Engineering, National Pingtung University of Science and Technology, Neipu Township, Pingtung 91201, Taiwan)

  • Jik Chang Leong

    (Department of Vehicle Engineering, National Pingtung University of Science and Technology, Neipu Township, Pingtung 91201, Taiwan)

Abstract

The significant amount of heat generated during the discharge process of a lithium-ion battery can lead to battery overheat, potential damage, and even fire hazards. The optimal operating temperature of a battery ranges from 25 °C to 45 °C. Hence, battery thermal management cooling techniques are crucial for controlling battery temperature. In this work, the cooling of 21700 lithium-ion batteries during their discharging processes using phase-change materials (PCMs) and porous pure copper foams were simulated. The effects of discharge intensities, battery orientations, and battery arrangements were investigated by observing the changes in temperature distributions. Based on current simulations for a 2C discharge, air-cooled vertical batteries arranged in unidirectional configuration exhibit an increase in heat dissipation by 44% in comparison to the horizontal batteries. This leads to a decrease in the maximum battery temperature by about 10 °C. The use of either PCMs or copper foams can effectively cool the batteries. Regardless of the battery orientation, the maximum battery temperature during a 2C discharge drops dramatically from approximately 90 °C when air-cooled to roughly 40 °C when the air is replaced by PCM cooling or when inserted with a copper foam of 0.9 porosity. If the PCM/copper foam approach is implemented, this maximum temperature further decreases to slightly above 30 °C. Although not very significant, it has been discovered that crossover arrangement slightly reduces the maximum temperature by no more than 1 °C. When a pure copper foam with a porosity ranging from 0.90 to 0.97 is saturated with a PCM, the excellent thermal conductivity of pure copper, combined with the PCM latent heat absorption, can best help maintain the battery pack within its range of optimal operating temperatures. If the porosity of the copper foam decreases from 0.95 to 0.5, the volumetric average temperature of the batteries may increase from 30 °C to 31 °C.

Suggested Citation

  • 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.
    • Handle: RePEc:gam:jeners:v:17:y:2024:i:7:p:1553-:d:1362906
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    References listed on IDEAS

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    1. Ling, Ziye & Chen, Jiajie & Fang, Xiaoming & Zhang, Zhengguo & Xu, Tao & Gao, Xuenong & Wang, Shuangfeng, 2014. "Experimental and numerical investigation of the application of phase change materials in a simulative power batteries thermal management system," Applied Energy, Elsevier, vol. 121(C), pages 104-113.
    2. Liu, Xun & Zhang, Chen-Feng & Zhou, Jian-Gang & Xiong, Xin & Wang, Yi-Ping, 2022. "Thermal performance of battery thermal management system using fins to enhance the combination of thermoelectric Cooler and phase change Material," Applied Energy, Elsevier, vol. 322(C).
    3. 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.
    4. Jilte, Ravindra & Afzal, Asif & Panchal, Satyam, 2021. "A novel battery thermal management system using nano-enhanced phase change materials," Energy, Elsevier, vol. 219(C).
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    1. Jun Chen & Wanli Xu & Hao Tian & Yichao Cao & Jincheng Gu & Haijun Zhou & Yong Jin, 2025. "Review on Lithium-Ion Battery Heat Dissipation Based on Microchannel–PCM Coupling Technology," Energies, MDPI, vol. 18(3), pages 1-16, January.
    2. Sevgi Aydın & Umut Ege Samancıoğlu & İsmail Hakkı Savcı & Kadri Süleyman Yiğit & Erdal Çetkin, 2025. "Impact of Cooling Strategies and Cell Housing Materials on Lithium-Ion Battery Thermal Management Performance," Energies, MDPI, vol. 18(6), pages 1-18, March.

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