Abstract:

Efficient thermal management is very critical for the performance, safety, and longevity of lithium-ion batteries in high-demand applications such as electric vehicles. This paper proposes a compact hybrid battery thermal management system that incorporates nanofluid-based cooling, phase change materials, and novel pulsed flow function to increase heat dissipation. The proposed system is composed of U-shaped microchannels with the incorporation of PCM/aluminum foam to achieve compactness with efficient thermal regulation. A validated model of thermal-fluid dynamics evaluates the effect of coolant type and flow rate, channel dimensions, and cooling direction on thermal performance. Results show that NC+PCM+EC hybrid cooling reduces maximum battery surface temperature by as much as 3.44°C relative to conventional liquid cooling, with only a 5% penalty in power consumption. The system also increases battery charge cycles by up to 6% to 15%, therefore boosting energy efficiency and safety of the vehicle tremendously. This study forms the foundation of next-generation cooling solutions for advanced battery applications