What does this research mean for the field?

A hybrid battery thermal management system integrating a helical mini-channel with copper-foam-enhanced phase change material significantly reduces lithium-ion battery surface temperature, outperforming pure phase change material by 92.46% and liquid cooling by 22.5%. Novelty: ClaimNovelty.NOVEL_FINDING. Consensus alignment: ConsensusAlignment.NEUTRAL.

What question did this study set out to answer?

To develop and optimize a hybrid battery thermal management system combining helical mini-channel liquid cooling and copper-foam-enhanced phase change materials for lithium-ion batteries.

August 23, 2026Journal of Energy StorageOpen Access

Optimization of hybrid thermal management system in electric vehicle lithium-ion battery using mini-channel cooling and copper-foam-enhanced phase change material

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Authors

FMFatemeh MotevasseliUniversity of Mohaghegh Ardabili MVMohammad VajdiUniversity of Mohaghegh Ardabili KVKourosh VaferiUniversity of Mohaghegh Ardabili

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Implication

Computational study reveals that combining helical mini-channels with copper-foam phase change material minimizes lithium-ion battery temperatures, highlighting improved electric vehicle safety.

Key Points

To develop and optimize a hybrid battery thermal management system combining helical mini-channel liquid cooling and copper-foam-enhanced phase change materials for lithium-ion batteries.
Evaluated passive, active, and hybrid cooling configurations for a single 26,650 lithium-ion battery and scaled the optimal design to a 9-battery pack.
Investigated geometric design parameters of helical mini-channels, paraffin RT-35 phase change material, and copper foam.
Optimized cooling performance and surface temperature reduction using numerical simulations, artificial neural networks, and genetic algorithms.
The optimized hybrid thermal management system achieved the lowest surface temperature among all evaluated passive, active, and hybrid configurations.
The optimal hybrid design improved temperature reduction performance by 92.46% compared to pure phase change material.
The hybrid cooling configuration demonstrated a 22.5% performance enhancement over standalone mini-channel liquid cooling.

Cite This Study

Motevasseli et al. (2026) studied this question.

synapsesocial.com/papers/6a8aadc57677a341144461f8 https://doi.org/10.1016/j.est.2026.124063

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Implication

Computational study reveals that combining helical mini-channels with copper-foam phase change material minimizes lithium-ion battery temperatures, highlighting improved electric vehicle safety.

Optimization of hybrid thermal management system in electric vehicle lithium-ion battery using mini-channel cooling and copper-foam-enhanced phase change material

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Cite This Study

Optimization of hybrid thermal management system in electric vehicle lithium-ion battery using mini-channel cooling and copper-foam-enhanced phase change material

Discussion

Member takes

Implication

Key Points

Cite This Study

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