Enhancing Li‐Ion Electric Vehicle Battery Performance: Analysis of Advanced Thermal Management Cooling Strategies with Phase Change Material

Abstract

Battery thermal management systems (BTMSs) are crucial for modern electric vehicle (EV) battery design, impacting system complexity, cost, and performance. This study calculates thermal performance using advanced computational analysis, employing a standard k‐ε turbulence model to simulate two cooling system setups: active and passive techniques utilizing phase change material (PCM). PCM with air cooling exhibits the lowest performance among hybrid BTMS setups, failing to maintain battery temperature uniformity. Conversely, PCM with n‐heptane, water cooling, and single liquid cooling (n‐heptane) achieve optimal battery module temperature ranges (20–40 °C) while preserving uniformity. Compared to noncooling configurations, the PCM + n‐heptane arrangement reduces Li‐ion battery module temperatures by 3.422, 10.261, and 28.33 °C at 1‐C, 2‐C, and 5‐C discharge rates, respectively. However, maximum temperatures at higher discharge rates (10C and 15C) remain elevated (350–380 K) with shorter discharge periods. The study highlights the necessity of appropriate cooling systems for battery thermal management to enhance performance and lifespan in EVs. Hybrid BTMS, particularly utilizing PCM, emerges as superior in maintaining uniform battery temperatures. Optimization strategies, including controlling coolant pump energy consumption and designing coolant pipes, are vital for efficient thermal management in diverse environmental conditions.