Performance Analysis of a Hybrid ATEC/PCM Thermal Management System for Battery Packs

Phase change materials (PCMs) provide advantages such as high energy storage density and passive operation for battery thermal management systems (BTMS). However, they face significant limitations under high discharge rates and thermal runaway scenarios, including inadequate temperature control duration and an inability to suppress thermal runaway propagation. To address these challenges, this study proposes a novel BTMS that integrates an annular thermoelectric cooler (ATEC) into a PCM‐based system. The annular geometry of the ATEC facilitates easier integration compared to conventional flat‐plate designs. Key findings include: (1) The ATEC achieves peak cooling performance with an optimal geometry (leg length = 1.2 mm, circumferential angle = 8°, thickness = 1.2 mm), exhibiting minimal performance degradation under varying thermal loads; (2) the integration of six fins within the system optimizes heat transfer and temperature uniformity; and (3) applying a 3 A current to the ATEC effectively maintains the battery temperature below 45°C under high discharge rates while maximizing PCM utilization. Crucially, during thermal runaway events, the proposed ATEC–PCM–BTMS operating at 3 A not only suppresses propagation effectively but also maintainsa high coefficient of performance.