Numerical Investigation of a Novel Hybrid PCM-Liquid Cooling Battery Thermal Management System

Electric vehicles offer a solution to the pressing issues of energy crises and environmental pollution. A crucial component of electric vehicles is the battery thermal management system, which maintains the battery cells at their optimal operating temperature. This regulation directly impacts the driving range, extends the lifespan of the cells, and enhances overall system safety. In this study, we propose a novel thermal management system that utilizes microchannels and phase change materials. The proposed design utilizes the void spaces between battery cells to integrate straight microchannels parallel to the battery axis, while the remaining spaces are filled with paraffin PCM to enhance thermal uniformity and safety. The results showed that, for this setup, the battery temperature does not increase from its initial temperature more than 5.27 K in the battery pack, which is desirable for the battery thermal management systems. This innovative system not only maximizes the use of available space for cooling but also ensures that the entire battery pack is cooled uniformly. In this study, the performance of the proposed system was investigated numerically, and it was found that this system has great potential for commercial applications.