Optimizing Thermal Management Systems to Extend Battery Life of Electric Aircraft

This study investigates the relationship between thermal management system design and battery life in electric aircraft. While typical approaches size thermal management systems for maximum heat extraction during climb, this paper examines alternative strategies to size thermal management systems that maintain cell temperatures within safe limits while reducing the rate of diminishing performance. The analysis incorporates system-level interactions, where the mass of the thermal management system has a non-negligible effect on propulsion requirements while drawing additional power from the battery pack. Through a detailed examination of multiple configurations and Latin hypercube sampling of the design space, this study explores how the resulting thermal and current profiles influence battery pack life. Sensitivity analysis reveals that while reservoir volume predominantly affects the weight, the thermal management system as a whole has a consequential influence on battery life through direct and coupled effects. These findings provide insights into optimal thermal management system designs that balance weight with heat removal potential to maximize battery life.