Enhanced thermal management of lithium-ion pouch cells via hybrid approach of phase change material-liquid cooling

Sen, Surojit; Mahdi, Jasim M; Talebizadehsardari, Pouyan; La Rocca, Antonino; Cairns, Alasdair

Abstract

Effective thermal management is crucial for safe, high-performance operation of lithium-ion batteries in electric vehicles (EVs). However, conventional passive or active cooling methods alone struggle to provide sufficient heat dissipation while maintaining uniform battery temperatures. This computational study investigates a hybrid thermal management system combining lateral phase change material (PCM) layers for temperature stabilization with vertical liquid cooling channels. The system was evaluated for a lithium-ion pouch cell module with PCM thicknesses ranging from 1 to 7 mm (melting point 26 °C) and a 0.5 mm liquid coolant channel using Novec-774 at 15–20 °C inlet and 90 lpm flow rate. Key findings reveal the 7 mm PCM achieved superior thermal regulation, constraining mean/maximum cell temperatures to 32.5 °C/39.1 °C compared to 113.8 °C/188.1 °C for the ineffective 1 mm case. Lower coolant inlet temperatures further enhance the performance, with a 5 °C inlet yielding 24.6 °C/29.2 °C mean/max, versus 26.0 °C/29.8 °C at 15 °C inlet. The hybrid passive-active approach combines lateral heat absorption via PCM with vertical forced convection cooling to effectively regulate battery temperatures. The proposed approach achieves superior cooling with up to 73 % reduction in maximum temperature compared to conventional liquid cooling, while maintaining temperature uniformity within 5 °C across the battery module.

Citation

Sen, S., Mahdi, J. M., Talebizadehsardari, P., La Rocca, A., & Cairns, A. (2025). Enhanced thermal management of lithium-ion pouch cells via hybrid approach of phase change material-liquid cooling. International Communications in Heat and Mass Transfer, 165(A), Article 108997

• Journal Article Type: Article
• Acceptance Date: Apr 27, 2025
• Online Publication Date: May 8, 2025
• Publication Date: 2025-06
• Deposit Date: May 6, 2025
• Publicly Available Date: May 9, 2025
• Journal: International Communications in Heat and Mass Transfer
• Print ISSN: 0735-1933
• Electronic ISSN: 0735-1933
• Publisher: Elsevier
• Peer Reviewed: Peer Reviewed
• Volume: 165
• Issue: A
• Article Number: 108997
• Keywords: Lithium-ion battery, Thermal management, Phase change material, Liquid cooling
• Public URL: https://nottingham-repository.worktribe.com/output/46467578
• Publisher URL: https://www.sciencedirect.com/science/article/pii/S0735193325004233