Parametric Analysis of Dual‐Path Thermal Management in Hybrid Battery Thermal Management System Using Layered Metal Foam

The low thermal conductivity of phase change materials (PCMs) fundamentally restricts the thermal performance of hybrid battery thermal management systems particularly under high discharge rates. To address this while minimizing system weight and cost, a novel lightweight architecture is proposed that embeds discrete layered metal foam (MF) structures within PCM integrated with a liquid cooling plate. Unlike conventional fully saturated MF composites, this configuration enhances effective thermal conductivity without excessive material usage. Numerical simulations conducted under 5 C discharge conditions demonstrate that the layered MF establishes a dual‐path heat transfer mechanism which reduces the peak battery temperature from 48.03°C to 43.46°C. Parametric analysis reveals that increasing the number or thickness of layers or decreasing foam porosity further improves thermal control but with diminishing marginal returns. In addition, critical operational trade‐offs are identified. Increasing coolant flow rate lowers peak temperature but worsens spatial temperature uniformity, whereas raising coolant inlet temperature enhances both PCM utilization and temperature uniformity with only a minor increase in maximum temperature. This work provides a practical design framework for developing lightweight hybrid thermal management systems that balance cooling efficiency temperature uniformity and energy consumption for high‐power lithium‐ion battery packs.