Innovative 3D-printed hybrid cooling systems for thermal management of lithium-ion pouch cells
Xuguang Zhang, Michael C. Halbig, Amjad S. Almansour, Mrityunjay Singh, Meelad Ranaiefar, Yi Zheng
Abstract
Robust and innovative thermal management technologies are critical for ensuring the safety, performance, and long-term use of lithium-ion pouch cells (LIPCs), particularly under high-power operations. Conventional battery thermal management systems (BTMS) often struggle to balance thermal regulation efficiency with structural simplicity, necessitating the development of hybrid cooling approaches. This work introduces an advanced hybrid BTMS that integrates liquid cooling with composite phase-change material (CPCM)-based thermal buffering, leveraging a 3D-printed hexagonal structure for optimized heat dissipation. This novel design maximizes contact between the CPCM and liquid cooling pathways while ensuring structural integrity and preventing leakage through a two-step additive manufacturing process. Experimental results demonstrate that the hybrid cooling system significantly reduces peak cell temperatures by up to 35 °C compared to standalone cooling methods, effectively mitigating thermal runaway risks and enhancing battery reliability. The incorporation of nanocarbon-enhanced CPCM further improves thermal conductivity, accelerating heat absorption and dissipation. By offering a scalable and lightweight solution, the proposed hybrid BTMS presents a viable pathway for next-generation high-energy-density LIPC applications, such as electric vehicles and grid-scale energy storage.