Analysis of hybrid active-passive prismatic Li-ion battery thermal management system using phase change materials with porous-filled mini-channels

The rapid expansion of electric vehicles (EVs) has created a significant demand for lithium-ion batteries (LIBs). However, ensuring safety and preventing thermal degradation of LIBs pose challenges to their overall performance and lifespan. Efficient battery thermal management systems (BTMS) are crucial in achieving long-lasting batteries with high energy density. Thermal management procedures are categorized into active and passive approaches. While active cooling methods are crucial, they consume power. Instead, passive cooling methods are not as influential in fulfilling all roles. This study examines a combination of active (mini-channel) and passive (PCM heat sink) techniques. The effects of employing a porous medium inside the mini-channel are also analyzed to enhance the heat exchange. Influences of different factors, including Darcy number, material, the thickness of porous media, and inlet velocity of mini-channel flow in multiple discharge rates (1C, 2C, 3C), are examined. Outcomes show the PCM heat sink itself can lessen the maximum temperature by about 4.2 to 5 K in different inlet velocities. The hybrid porous-filled channel and PCM heat sink can mitigate the maximum temperature by about 13 K in different inlet velocities and at the maximum discharge rate (3C) at the expense of about 14 % higher pumping power in different conditions.