Cooling Performance of Hybrid Thermal Management System for the Large‐Capacity LiFePO ₄ Battery

This study develops a composite sandwich‐type thermal management system integrating aerogel, liquid cooling, and heat pipes to optimize lithium‐ion battery (LIB) module performance while balancing heat dissipation and thermal runaway prevention. The hybrid system couples aerogel insulation with a bottom‐mounted liquid cooling plate, significantly reducing peak temperatures and improving thermal uniformity. Key parameters investigated include coolant flow rates (25 and 200 mL/min) and aerogel thickness (0–3 mm). By incorporating heat pipes (high‐efficiency passive heat transfer devices) and optimizing coolant velocity, the system achieves enhanced thermal dissipation efficiency. Experimental results demonstrate that at a flow rate of 200 mL/min with 1 mm aerogel, the LIB module maintains a maximum temperature of 41.6 °C and temperature difference of 4.6 °C, meeting operational requirements. The integrated design not only ensures effective thermal control during normal operation but also shows promising capability to suppress thermal runaway propagation (uncontrolled chain reaction of battery overheating), significantly improving LIB safety. This work presents a practical solution for advanced battery thermal management that simultaneously addresses cooling performance and safety concerns.