Improved Thermal Management of Li-Ion Batteries with Phase-Change Materials and Metal Fins

The continuing increase in pollutant emissions requires the use of alternative power sources. This includes the use of electric or hybrid vehicles whose energy storage system is based on batteries of various types, including lithium-ion batteries. The optimum operating temperature is between 15 °C and 35 °C. Too high temperatures can lead to catastrophic phenomena such as thermal runaway. The thermal gradient within the system should not exceed 5 °C. An effective Battery Thermal Management System can mitigate this problem. This study analysed a lithium-ion battery with a bag structure. Temperature control was evaluated using a passive (low-cost) system with phase-change materials (PCMs). The material chosen was n-octadecane (paraffin) due to its thermophysical properties and market price. Four different cooling methods were analysed, including air, fins, pure PCM, and a mixed system of single cells and small battery packs. The results show that an undesirable temperature peak around 50 °C (323.15 K) can occur at hot spots. The best system for containing the temperature inside the battery pack is the PCM cooling system with fins. The optimum fin thickness is 1.5 mm. To contain the temperature inside the battery pack, the number of fins studied is 10, while the best temperature containment is achieved with n+ 1 plates, where n is the number of cells.