Design and performance of a compact lightweight hybrid thermal management system using phase change material and liquid cooling with a honeycomb-like structure for prismatic lithium-ion batteries

This study presents a compact and lightweight hybrid battery thermal management system (BTMS) that integrates phase change materials (PCM) with liquid cooling in a honeycomb-like configuration, specifically designed for prismatic lithium-ion batteries. A validated mathematical model compared various PCM cell shapes within the hybrid BTMS, evaluating thermal distribution and the influence of key operating parameters. Findings reveal that PCM cell shape minimally impacts temperature control but significantly affects pressure drop and performance evaluation criteria (PEC). Design 1, with a hexagonal PCM configuration, exhibited the highest comprehensive heat transfer performance, with PEC values 30.7 % higher than Design 2 and 7.8 % higher than Design 3. The hybrid BTMS reduced battery temperature and system mass by 15.3 % compared to liquid cooling BTMS. During steady PCM melting, coolant mass flow rate m co minimally impacted maximum temperature T max and temperature difference Delta T max , with both parameters remaining constant. Increasing m co from 0.2 g s- 1 to 0.8 g s- 1 , reduced T max and Delta T max by 10.7 K and 9.8 K, respectively. Inlet coolant temperature T in showed similar trends for T max but differed for Delta T max . As T in decreased from 303.0 K to 298.0 K, T max decreased by 1.2 % but Delta T max increased by 13.1 %. 2C and 3C discharge rates kept T max below 313 K, with 2C maintaining Delta T max within the required 5 K limit.