Sustainable and Eco-Friendly Battery Thermal Management System Based on Hybrid Cooling for Electric Vehicles

Lithium-ion batteries are a crucial component of electric vehicles (EVs), directly impacting their performance, safety, and efficiency. To function optimally, these batteries require precise thermal regulation, maintaining an operating temperature between 15°C and 35°C during both charging and discharging cycles. Keeping the battery within this range extends its lifespan, reduces thermal stress, and minimizes the risk of overheating, which can lead to thermal runaway—a significant safety concern in EV applications. However, existing cooling methods, including air cooling, liquid cooling, phase change materials (PCM), and nanofluid integration, have limitations, especially when exposed to diverse operating conditions and environments. This study introduces an innovative hybrid cooling system that integrates liquid cooling and forced air cooling with evaporative cooling. By utilizing forced air to enhance evaporative cooling, this approach maintains a continuous cooling effect, while liquid cooling efficiently dissipates excess heat to ensure stable temperatures. Beyond improving thermal management, this system helps extend battery life, optimize energy efficiency, and lower the risk of overheating. Its compact design also makes it adaptable for various EV applications, such as passenger vehicles, commercial fleets, public transportation, and stationary energy storage solutions. With its ability to accommodate different thermal demands, this hybrid cooling system presents a highly adaptable and reliable solution for EV technology. By improving battery performance and longevity, it aligns with industry goals to create safer, more durable, and environmentally friendly electric vehicles, ultimately accelerating the transition to sustainable transportation.