Hybrid thermal management system for e-bike controllers using phase change materials and metal foams: A numerical study

• Hybrid cooling system combining PCM, metal foams, and forced air for electric bicycle controllers. • Validated LTNE numerical model used to evaluate transient thermal performance. • Optimized design kept controller temperature <49°C under 100 W load for 75 min. • Metal foam improved thermal uniformity by enhancing conduction and limiting hotspots. • Forced airflow extended PCM effectiveness, delaying saturation by over 28%. • Adequate PCM volume above the controller proved critical to delay saturation and extend operation under optimal conditions. This work presents the development and numerical evaluation of an innovative hybrid thermal management system for e-bike electronic controllers, combining phase change materials (PCM), metal foams, and forced air convection. The proposed system addresses the thermal limitations of conventional passive cooling under high load conditions, which may compromise the reliability and safety of compact electronic components. A commercial paraffin-based PCM (RT45HC) was selected for its high latent heat and suitable melting range (45–48°C) while open-cell aluminum foams were employed to enhance thermal performance and mitigate the formation of hotspots. Several design iterations were numerically analyzed using a validated transient local thermal non-equilibrium (LTNE) model. The results demonstrate that the optimal configuration, featuring lateral air-cooled channels and centralized controller placement, maintains the component temperature below 49°C for 75 minutes of continuous operation with a 100 W thermal load. The foam’s properties were found to significantly influence heat transfer by promoting conduction and natural convection within the PCM. Additionally, the study confirms the critical role of active airflow in extending PCM effectiveness and delaying thermal saturation, enabling an extension of the operating period by more than 28%. These findings highlight the potential of the proposed system as a compact, efficient, and scalable solution for thermally demanding applications in electric mobility.