Synthesis, characterization and performance analysis of nano-enhanced phase change material for battery thermal management application

The development of advanced materials is highly important for the efficient thermal management of battery packs. The present work addresses the synthesis and comprehensive evaluation of nano-enhanced phase change materials (NEPCMs) formed by uniformly dispersing CuO nanoparticles (1– 4 wt%) into an organic paraffin-based phase change material (PCM) (OM-42). The structure and morphology of the resulting composites were rigorously characterized via XRD, FT-IR, SEM, HRTEM, and EDS, confirming the successful incorporation and homogeneous distribution of the nanoparticles without compromising the chemical integrity of the PCM matrix. Thermal analyses revealed a substantial increase in the thermal stability of NEPCM. Alterations in phase change behavior were observed through broader melting transitions and delayed onset of thermal decomposition. The incorporation of CuO nanoparticles improved the thermal conductivity of the NEPCM by a maximum of 80%. The synthesized NEPCM was subsequently tested in a single mock-up cell. The temperature readings obtained through thermocouples and an infrared thermal imaging camera demonstrated that, compared with the pure PCM, the NEPCM substantially prolonged heat retention and provided more controlled temperature regulation. These results highlight the significant potential of CuO-based NEPCMs in overcoming the inherent restrictions of conventional PCMs, including their low thermal conductivity and rapid degradation. These findings position NEPCMs as promising and versatile solutions for the thermal management of lithium-ion battery packs. • The addition of CuO NPs to PCM (OM42) improved the stability, crystallinity, and matrix bonding. • The thermal conductivity of NEPCM improved by 80% with 4 wt% CuO. • The addition of CuO NPs enhanced the thermal stability of NEPCM and increased its degradation temperature. • The highest extension in operational time to reach 50 °C at the cell sleeve was 302% for the 4 wt% CuO NEPCM.