Battery thermal management of lithium-ion cells in hot regions using PCM and copper foam: A CFD simulation and thermo-techno-economic assessment

One of the primary challenges facing lithium-ion cells (LICs) is significant heat dissipation during operation, which can lead to increased temperatures and eventual failure. Despite their low thermal conductivity, phase change materials have recently become popular for their ability to store a large amount of heat in battery thermal management systems (BTMS). For the purposes of enhancing the effectiveness of PCM-based passive methods in hot climates, this CFD study seeks to design a conical-cylindrical housing (CCH) filled with PCM and copper foam specifically for hot climates. This numerical research investigates how variations in the top thickness (TT) and bottom thickness (BT) of the CCH, with and without copper foam, affect LIC performance. Results indicate that increasing TT and BT from 4 mm to 10 mm reduces the LIC maximum temperature (LICMT) by 20.2°C and 9.4°C, respectively. The thermo-techno-economic assessment (TTEA) also demonstrates that the proposed system is 21 and 480 times more cost-effective than traditional air-based methods at a C-rate of 2 and 4, respectively. The primary contribution of this work is the modification of PCM housing geometry and the incorporation of copper foam which will significantly improve the BTMS of LICs while being cost-effective.