Numerical investigation on thermal management system of lithium-ion battery pack of electric vehicles based on hybrid cooling of porous media, phase change materials, and liquid cooling

This study investigates a Hybrid Battery Thermal Management System (HBTMS) designed for lithium-ion battery packs in electric vehicles, integrating phase change material (PCM), metal foam, liquid cooling, and porous layers. The HBTMS aims to enhance thermal performance, manage high discharge rates, and ensure battery safety by minimizing thermal runaway risks. A three-dimensional computational fluid dynamics (CFD) model is employed to analyze the effects of different configurations and thicknesses of PCM and porous layers on key thermal metrics, such as maximum surface temperature, PCM liquid fraction, temperature uniformity, and heat transfer efficiency. The novelty of this work lies in the combined implementation of dual-porosity structures metal foam in the PCM region and porous inserts in the coolant channels which has not been comprehensively investigated in previous BTMS studies. This integrated design enables both enhanced latent heat utilization and superior convective cooling within a single system. Results indicate that the fully integrated HBTMS with PCM, metal foam, and liquid cooling significantly reduces maximum surface temperature to approximately 301 K under a 5C discharge rate, with a stable thermal profile. Compared to pure PCM, the addition of metal foam and liquid cooling delays the PCM's phase change, preventing rapid saturation and allowing for sustained heat absorption. Furthermore, increasing PCM thickness improves heat distribution and reduces maximum temperature differences, ensuring uniformity across the battery pack. The inclusion of a porous layer enhances convective heat transfer and reduces the system's reliance on PCM's latent heat alone. The Nusselt number and the performance evaluation criteria (PEC) analysis confirms optimal heat dissipation and efficient pressure management in the HBTMS, particularly with a 3 mm porous layer thickness. This comprehensive system outperforms conventional BTMS setups, showing enhanced temperature control and stability, essential for prolonged battery life and safe operation. The findings underscore HBTMS's potential for applications requiring robust thermal management.