Multifaceted thermal regulation in electrochemical batteries using cooling channels and foam-embedded phase change materials

Lithium-ion batteries are widely used in electric vehicles and grid energy storage systems. Compared to cylindrical batteries, prismatic cells are the primary choice because of their advantage for dense packing. However, thermal runaway and temperature inhomogeneities are the main thermal regulation problems that affect their reliability, safety, and useful life. Here, we propose and assess a multifaceted cooling system composed of water channels (active cooling) and metallic foam embedded with two types of phase-change materials or PCMs (passive cooling) with different melting points. We show that a multifaceted thermal regulation strategy can improve both cooling effectiveness and temperature homogeneity through a representative prismatic battery module. Our numerical results indicate that for a battery pack cooled with a water channel (3 C discharge rate), a dual-PCM arrangement can reduce the maximum temperature by 1.3 °C and 2.7 °C compared to a mono-PCM arrangement and a battery pack without PCM, respectively. The maximum temperature difference within the cell is also 1.2 °C. Therefore, multi-PCM thermal management systems show better performance than their mono-PCM predecessors in terms of lowering the maximum battery temperature and improving thermal homogeneity. This work motivates the development of multifaceted thermal management systems with active and passive cooling to improve the long-term performance of electrochemical battery cells. • Multifaceted thermal management improves lithium-ion battery safety and performance. • Integrating active liquid cooling with passive phase change materials is beneficial. • Dual-PCM module reduces maximum battery temperature up to 1.3°C than a mono-PCM one. • Improved thermal homogeneity and reliability are ensured in prismatic battery modules. • A Dual-PCM cooling system improves the temperature inhomogeneity up to 2°C.