Synergistic PCM–Liquid Thermal Management for Large-Format Cylindrical Batteries Under High-Rate Discharge

The push for higher energy density in electric vehicles has resulted in large-sized lithium-ion batteries, but their geometric upscaling exacts a heavy thermal price. Under high-rate discharge, these massive cells become heat traps, risking thermal runaway. To tame this instability, this paper engineered a hybrid management strategy fusing liquid cooling, Phase Change Materials (PCMs), and flow deflectors. With a primary focus on the structural optimization of the cooling channel, a three-dimensional numerical model, calibrated using experimentally determined thermophysical properties, was developed to overcome the thermal bottlenecks of conventional cooling architectures. Results indicated that the initial channel optimization effectively reduced the maximum temperature to 327.7 K, but it still remained near the safety threshold. Integrating PCM radically altered the thermal landscape, slashing the outlet temperature differential by 41.67% (from 2.76 K to 1.61 K) compared to pure liquid cooling and blunting peak thermal spikes. Furthermore, to overcome laminar stagnation, strategic deflector baffles were introduced to agitate the coolant, enhancing heat dissipation. Specifically, the optimal half-coverage (L = 1/2) baffle configuration successfully lowered the maximum temperature to 322.42 K while substantially reducing the system pressure drop from 948.16 Pa to 627.57 Pa, achieving a 33.33% reduction compared to the full-coverage scheme. Finally, a multi-variable sensitivity analysis confirmed the extraordinary engineering robustness of the optimized configuration, demonstrating a negligible maximum temperature fluctuation of less than 0.5% despite ±10% operational and material uncertainties. This synergistic system actively stabilizes the thermal envelope, offering a robust engineering blueprint for next-generation high-power battery packs.