Next‐Generation Fin‐Structured PCM Solutions for Effective Thermal Management of Li‐Ion Batteries

ABSTRACT The efficiency and effectiveness of a battery thermal management system (BTMS) primarily depend on the limited heat dissipation capacity of the phase change material (PCM). In this study, a novel extended‐surface PCM composite is designed to enhance the thermal management of lithium‐ion batteries. Numerical investigations using ANSYS Fluent reveal that incorporating metallic fins significantly improves heat transfer by creating a multichannel thermal network. The modified BTMS demonstrates a 92.5% increase in operational duration compared with conventional PCM systems. Additionally, increasing the fin length from 6 to 14 mm improves operational time by 13.62%, while uniform fin placement enhances thermal performance by 9.25%. At higher ambient temperatures (20°C–50°C), the system achieved a 1.96‐fold increase in operational duration compared with traditional setups. Furthermore, the optimized BTMS maintained the battery temperature below 60°C for 41%–93% longer durations across varying configurations, outperforming existing systems in high‐temperature environments. These findings validate the effectiveness of extended‐surface PCM composites in overcoming the limitations of conventional BTMSs, enhancing both battery performance and longevity.