Analysis of Hybrid Thermal Systems Incorporating Composite Phase Change Materials

Abstract The growing global population and rapid industrialization have increased fossil fuel demand, leading to resource depletion and environmental harm. The transportation sector, particularly conventional vehicles, significantly contributes to emissions. New energy vehicles, powered by renewable sources, present a cleaner alternative but depend on efficient energy storage. Pouch cell batteries, while promising, face thermal management challenges, including performance degradation and thermal runaway due to excess heat. This study investigates the thermal management of pouch cells using composite phase change materials (CPCMs), emphasizing the impact of container geometry and coolant ratios on system efficiency. A review of existing cooling strategies highlighted CPCMs combined with hexagonal packing as particularly effective. Numerical simulations were conducted using three CPCM-to-coolant ratios (1:1, 1:2, and 1:3), three geometric configurations (square, circular, hexagonal), and two unit densities (2 rows of 10 units and 3 rows of 23 units). Results indicate that higher coolant ratios and denser, hexagonal configurations offer superior thermal regulation, minimizing hotspots and ensuring uniform temperature distribution. Optimization of both material distribution and geometric arrangement significantly enhances battery safety and efficiency. These findings provide valuable insights for the design of high-performance, sustainable battery systems in new energy vehicles and contribute to ongoing efforts toward electrified, low-emission transportation.