Enhanced battery thermal management using nano-PCM, copper foam, and aluminum minichannels: An optimized hybrid approach
Nassreddine Hmidi, Ahmed Alami Merrouni, Satyam Panchal, Roydon Fraser, Michael Fowler, Abdel-illah Amrani, Elmiloud Chaabelasri
Abstract
In recent years, electric vehicles (EVs) and hybrid electric vehicles (HEVs) have emerged as viable alternatives to fuel-powered vehicles. However, effective thermal management is crucial for the batteries in these vehicles to ensure optimal performance, safety, and longevity. This study presents an optimized Battery Thermal Management System (BTMS) that integrates phase change materials (PCM) with aluminum minichannels to enhance heat dissipation. A systematic investigation is conducted to determine the optimal PCM thickness, the influence of multi-walled carbon nanotube (MWCNT) nanoparticles added to PCM to improve thermal conductivity, the role of copper foam as a porous medium, and the effect of coolant inlet velocity in minichannels on overall system performance. The results indicate that the integration of a 5 mm of nanoPCM with 8 % MWCNTs, 95 % porosity copper foam, and a coolant inlet velocity of 0.35 m/s effectively regulates battery temperature, maintaining the maximum battery temperature (Tb,ₘₐₓ) at 32.47 %, with a maximum temperature difference (ΔTb,ₘₐₓ) of 1.99 °C. Compared to existing designs, the optimized BTMS demonstrates significant improvements in Tb,ₘₐₓ and ΔTb,ₘₐₓ. Furthermore, the system maintains reliable performance across varying ambient temperatures, ensuring safe and efficient battery operation.