Experimental Evaluation of Phase Change Materials on the Cooling Performance of Cylindrical Battery Modules

This study involved connecting four 18650 cylindrical lithium-ion batteries in series. An ABS structure produced using a 3D printer was then filled with salt hydrate phase change material (PCM). The batteries were then tested in two separate systems: one containing PCM and one without. In the PCM-enhanced system, the maximum surface temperature did not exceed 46 °C during discharge at a constant current of 8 A, corresponding to a discharge rate of 2.85 C. In the PCM-free system, the maximum surface temperature reached 66.3 °C under the same discharge condition. This resulted in improved battery performance by reducing temperature rise and enhancing discharge behavior under high-rate operating conditions. Furthermore, using PCM increased the batteries’ energy output by 20% during discharge at a constant 2.85 C rate. Finally, a techno-economic and environmental analysis was conducted to assess the system’s suitability for micro-mobility applications with a 1 kWh capacity. The system reached the break-even point in 4 years and 2 months, indicating that it is economical and feasible.