Simulations on hybrid thermal management of mini-channel cold plate and PCM for lithium-ion batteries under discharging and thermal runaway conditions

Abstract

In this study, we compared the performance of different structures of mini-channel cold plate (MCP) - phase change material (PCM) hybrid thermal management on discharge and thermal runaway. The heat transfer structures for them can be categorized into three types: (a) uncoupled, (b) semi-coupled, and (c) fully coupled. Among these, the semi-coupled design B exhibits the best performance. Specifically, in the high rate discharge condition, the structure can control the battery temperature at 44.37 °C at low coolant mass flow rate, and the temperature at 36.47 °C at high mass flow rate, while the temperature difference (TD) of a single cell does not exceed 2.01 °C. In a low-multiplier discharge zero-energy system, the pack temperature rise can be limited to no more than 10 °C in 35 °C environment. Under external short-circuit conditions, a lower coolant mass flow rate is sufficient to keep the pack temperature at 43.22 °C. Under internal short-circuit thermal runaway (TR), lower coolant mass flow rate can prolong the TR of the adjacent cell up to 521 s, and higher mass flow rate can completely inhibit the occurrence of TR. The objective of this study is to offer valuable references for the design and implementation of hybrid MCP-PCM cooling systems.