Thermal management is critical for maintaining the safety and performance of lithium-ion batteries. Phase change materials (PCMs) have been widely studied as passive cooling media due to their high latent heat capacity, but major technical challenges remain due to their relatively low thermal conductivity and nanoparticle sedimentation in composite systems. In this work, a composite phase change material (PCM) consisting of paraffin wax, a microencapsulated phase change material (MicroPCM 28D), and nano carbon black is developed to enhance thermal stability and suppress particle sedimentation through increased viscosity of the PCM matrix. Five capsule geometries fabricated by fused filament fabrication (FFF) 3D printing are experimentally investigated under airflow velocities ranging from 0 to 10 m s−1. Wind tunnel experiments with infrared thermography are used to evaluate the thermal response of the PCM capsules. The results show that airflow velocity and capsule geometry strongly influence heat dissipation behavior. Compared with conventional wax composites, the MicroPCM 28D composite capsules reduce peak temperature by approximately 2–4 °C under airflow velocities of 0–10 m/s. These findings provide insights into geometry-regulated convection and stable composite PCM design for lithium-ion battery thermal management systems.
Zhang et al. (Sat,) studied this question.