Analytical Thermal Model Research Articles

Study on temperature rise characteristics of DC charging cable for electric vehicles

In order to accurately calculate the relationship between the loading current and temperature rise of DC charging cable of electric vehicles, this article establishes the equivalent thermal circuit model of DC charging cable of electric vehicle based on the thermal circuit model analysis method, and refers to the principle of adaptive filtering, proposes a method to derive the thermal circuit model parameters of DC charging cable of electric vehicle from the actual temperature rise data, and designs a comparison experiments to verify the accuracy of the thermal circuit model of DC charging cable obtained by this method. The experimental results show that the calculation temperature rise and actual temperature rise error of the EV charging cable thermal circuit model obtained by deriving from the actual temperature rise data in this article is small, which verifies that the EV DC charging cable thermal circuit model obtained by this method has a certain accuracy in analyzing the temperature rise of this type of cable.

An Artificial Neural Network-based model that can predict inpatients’ personal thermal sensation in rehabilitation wards

Indoor thermal comfort is important to hospital designs as it affects healthcare outcomes. However, existing thermal sensation analysis models do not fully consider individual patient's preference and their effectiveness has not been validated in healthcare environments. The commonly used Predicted Mean Vote (PMV) model cannot process complex parameters such as individual differences, multiple patients' biosignals, medical activities, and spatial layout of wards, etc. To fill in the gaps, this research aims to develop an innovative model that can effectively predict in-patients' personal thermal sensation in rehabilitation wards. Based on previous research on machine learning (ML), a prototype of the Artificial Neural Network (ANN)-based model has been developed for this purpose. To test this model and assess its prediction accuracy in the real world, a case study was conducted in the rehabilitation department of a general hospital in Xuzhou, China. The results indicated that the ANN-based model effectively predicted patients' thermal sensation. Moreover, it was found from this study that the incorporation of spatial and health-related parameters into the ANN-based model could significantly improve the prediction accuracy. The best prediction accuracy of the ANN-based model was 8.10 % higher than that of the baseline model. It is therefore concluded that this model can be used to support architects and HVAC system engineers to make informed decisions in hospital designs and help medical staff allocate in-patients according to their preference.

Interlayer spacing control strategy to construct the rapid thermal conductivity channel in the molten salt phase change materials

With the goal of improving the thermal conductivity of inorganic salt PCMs without significantly affecting the thermal energy storage density, a functionalized modification strategy to regulate the layer spacing of nano two-dimensional (2D) materials was proposed to construct a thermal conduction pathway in phase change materials (PCMs). In the instance of graphene, we proposed hydroxylation to increase the lamellar spacing between graphene, improve its dispersion in molten salt PCMs, and speed heat transfer of graphene composite molten salt. When compared to pure graphene, the addition of hydroxylated graphene (GOH) improved the thermal conductivity of PCMs significantly. The thermal conductivity model demonstrated that the thermal conductivity pathway can be constructed by equally dispersing enough GOH to further increase the thermal conductivity. When the GOH percentage was 0.8 %, the composite's thermal conductivity was 2.60 W/(m·K), which was 118.5 % greater than the graphene composite with the same content. When the melting point was 240.00 °C, the composite material had a high latent heat of 355.52 J/g. The morphology characterization and thermal conductivity model analysis show that adjusting the layer spacing can improve graphene dispersion, facilitating the construction of thermal conduction pathway in PCMs, accelerating heat transfer, and essentially maintaining PCMs' original thermal energy storage density. Therefore, the strategy of regulating the layer spacing of 2D materials in this study has the potential to extend the application of other 2D materials used in PCMs to improve the heat storage properties.

Thermal-dynamic coupling analysis of space truss antennas in actual space thermal environment

Space truss antennas may undergo thermally induced vibration due to temperature changes caused by thermal mutations in the space environment, which will result in antenna performance degradation or even vibration failure. This paper aims to investigate the thermal-structural coupled dynamics of a space truss antenna in the orbital space thermal environment. A spatial thermal analysis model is established based on the spatial heat flux model, Fourier-temperature element, finite element method (FEM) and astrometric model to calculate temperature variation of the antenna structure during its operation in orbit. In this model, the effective solar heat flux received by the antenna structure is calculated on the basis of an astrometric model, with consideration of the Earth's shadow effect and the shading effect of the reflective surfaces. Additionally, a thermo-structural coupled dynamic model of the antenna structure is constructed considering the coupled effects of structural deformation and absorbed effective solar heat flux, which was validated using a finite element shell model. Numerical cases are arranged to comparatively analyze the thermal-structural coupling effects, light shading by reflective surfaces, and thermodynamic response during the space operation cycle, respectively. It is demonstrated that both the earth shadow effect and the shading effect of components have great effect on the temperature distribution and variation of the antenna structure. Moreover, significant vibrations will occur at certain moments especially when the thermal radiation flux to the structural components changes suddenly due to light shading from the earth shadow and reflective surfaces. The thermal-structural coupling dynamic model of the antenna structure presented in this work can provide guidance for thermal compensation and thermal-induced vibration attenuation of truss antenna structures.

Integrated composite electrothermal de-icing system based on ultra-thin flexible heating film

Icing is a serious threat to the flight safety of aircraft. Lightweight and efficient electrothermal de-icing systems for carbon fiber reinforced polymer components are expected to contribute to the lightweighting and electrification of aircraft. This study presents the development and test of a novel, integrated, multifunctional composite electrothermal ice protection system. The system achieves this by incorporating a carbon-based ultra-thin flexible heating film into a carbon fiber-reinforced polymer composite laminate. T700 and M40 carbon fiber prepregs were used. The system composition and configuration were designed based on the anisotropic mechanical and thermal properties of the carbon fiber-reinforced polymer composite. The effects of ply stacking sequence, presence of insulation layer, ply angle, heating area, and prepreg type on thermal response and de-icing performance were investigated. Thermal response experiments were carried out in both room temperature and low temperature environments. A one-dimensional thermal response analysis model was developed for a representative heating structure. Comparative de-icing experiments were conducted on different samples in a low-temperature test chamber. A numerical model, based on the modified enthalpy-porosity method, was developed to simulate the de-icing process, and showed good agreement with the experimental results. Experiments and numerical calculations show that the arrangement of the heater close to the deicing surface improves the performance of the electrothermal deicing system while maintaining the overall mechanical properties of the multi-layer structure. While the insulation layer helps marginally with heat loss during de-icing, it significantly increases the system’s thermal inertia, which delays the de-icing’s start. It is recommended to minimize or eliminate insulation layer thickness. Rapid de-icing effects, combined with energy conservation, can be achieved through a short-term, high-power heating strategy.

Thermal diffusion in discontinuous media: A hybrid peridynamics-based machine learning model

This paper introduces a novel hybrid formulation of a peridynamics-based machine learning model for thermal diffusion analysis in one-dimensional and two-dimensional problems with evolving discontinuities. The hybrid model employs a multivariate linear regression approach to establish the relationship between the temperature values of material points, their neighboring points, and the applied external heat flux. The thermal modal analysis method uses the finite element method to generate training and testing data. An efficient numerical procedure is also developed to couple the peridynamics model and the peridynamics-based machine learning model. The model is analyzed under multiple configurations of micro-thermal conductivity functions for one-dimensional thermal bar problems, under both steady-state and transient loading conditions, to identify the configuration that exhibits superior convergence behavior towards the local solution. Furthermore, benchmark problems demonstrate the high accuracy of the formulated hybrid model, including the analysis of thermal plates with discontinuities, such as a plate with a hole, a plate with a pre-existing insulated crack, and plate with a bi-material interface with stationary and evolving discontinuances. The hybrid model effectively captures intricate discontinuities and boundaries while being computationally efficient, indicating its potential for thermal diffusion analysis in one- and two-dimensional problems with stationary and evolving discontinuities.

Numerical thermal analysis of synchronous reluctance generator for wind energy application

AbstractThis paper focuses on the thermal analysis of the synchronous reluctance generator with a rating of 2.1 kW. It mainly uses explicit, and implicit finite difference methods for thermal analysis to reduce the complexity of thermal calculation for the machine's components. It compares the results with the results obtained using a finite element analysis (FEA) and includes the experimental verification of the obtained results. The explicit, and implicit finite difference thermal analysis is relatively simple and computationally fast. Once the design parameters are known, the electric losses and iron losses of the synchronous reluctance generator are evaluated. These machine parameters are utilized in developing the explicit finite difference (EFD), an implicit finite difference (IFD), and a 3D FEA model for thermal analysis. It is observed that the obtained results from the EFD, IFD, FEA, and experiments are very close to each other, and the temperature rise for the designed machine is within the desired and acceptable range.

Initiation of initial conditions in a model for thermal analysis of road pavement structures

W pracy rozpatrzono możliwość inicjacji warunków początkowych w modelu do analizy termicznej nawierzchni drogowej w warunkach niestacjonarnego przepływu ciepła. Procedura wymaga przeprowadzenia obliczeń dla odpowiednio długiego czasu inicjacji do uzyskania początkowego rozkładu temperatury, który jest podstawą dalszych analiz przepływu energii cieplnej. Główną część pracy stanowi prezentacja eksperymentu numerycznego przeprowadzonego dla czterech konfiguracji wartości parametrów modelu przepływu energii cieplnej w ośrodku wielowarstwowym, jakim jest nawierzchnia. Każda konfiguracja parametrów odpowiada innej konstrukcji (dwa modele nawierzchni podatnej i dwa modele z warstwą z pianobetonu). Obliczenia przeprowadzono kolejno dla trzech różnych wartości amplitud sinusoidalnej funkcji zmiany temperatury w czasie, którą zde- finiowano jako warunek brzegowy w modelu nawierzchni. Uzupełnieniem eksperymentu numerycznego były obliczenia przeprowadzone dla jednej wybranej konfiguracji wartości parametrów modelu, w którym warunek brzegowy stanowiły wartości temperatury zarejestrowane czujnikiem wbudowanym w nawierzchnię. Na podstawie analizy uzyskanych wyników potwierdzono, że inicjacja warunków początkowych w równaniu przewodzenia ciepła jest możliwa w oparciu o analizę niestacjonarnego przepływu ciepła przedstawioną metodą.

Peristaltic flow analysis of thermal engineering nano model with effective thermal conductivity of different shape nanomaterials assessing variable fluid properties

The current study is connected to a recent investigation regarding temperature-dependent viscous flow for various-shaped nanoparticles in a flexible tube. For velocity/pressure gradient/temperature, precise solutions have been determined. Cylindrical coordinates have been used to simulate the main flow problem, and the lubrication approximation method has been used to reduce the flow equations to ordinary differential equations (ODEs). For easier understanding, results are graphically discussed. Additionally, it can be seen that platelet-shaped particles have a smaller velocity field than brick- and cylinder-shaped particles. Further it is analyzed that if we add the specific brick-shaped nanoparticles to the fluid, the thermal conductivity of the fluid improves.

Seasonal scour and siltation induced spatiotemporal variations in riverbed sediment leakage coefficients as measured via the thermal tracer method

Riverbed scour and siltation can change the hydraulic conductivity and thickness of sediments, leading to notable spatiotemporal variations of groundwater–surface water interaction. However, correlated quantitative research on the dynamic leakage coefficient (LC) remains lacking under riverbed scour and siltation. Based on dynamic monitoring and analysis of sediment medium properties, river-groundwater levels, and temperature profiles in the section of Liao River, this study compared the applicable conditions of different thermal analytical models and identified spatiotemporal variations in the LC values induced by riverbed scour and siltation. The results showed that: (1) The thermal tracer method combined with river-groundwater level monitoring can effectively quantify spatiotemporal variations in the LCs of riverbed sediment. Based on the sediment temperature presents diurnal fluctuations and gradient characteristics in different seasons, the LCs in summer, spring, and autumn compared to winter in seasonally frozen regions should be calculated using transient and steady-state analytical solution models, respectively. (2) The LCs ranged from 0.47 to 24.90 × 10-6 s−1, showed larger temporal variability than spatial, increased from the river bank to the center, and had larger values in autumn and winter. (3) Distinct from previous findings, the riverbed underwent a scouring process associated with reductions in the incoming sediment coefficient as the river stage shifted from high to low, eroding the surface 4–8 cm of sediment. During this process, the LC increased by 40 to 420%. Further, the influence of riverbed scour and siltation on the LC varied by river section. Near the riverbank, the sediment LC was primarily controlled by hydraulic conductivity related to the coarsening of sediment lithology; however, it was influenced by variations in both sediment thickness and hydraulic conductivity near the riverbed center. Collectively, these results further understand the mechanisms underlying changes in the sediment LC induced by riverbed scour and siltation, as well as provide a scientific basis for ensuring the sustainable development of riverside water sources under such changes.

Innovative concept of splitting water flow rate of cross flow heat exchangers as a solution for reduction of non-uniformity effect – Thermal modelling and feasibility analysis

The water flow rate of water-air cross-flow Heat Exchangers (HXs) is split into various smaller flow rates in this research work, which circulates into several smaller HXs that are put together. In fact, as the non-uniformities in the airflow velocity distributions increase, the thermal performance declines. These non-uniformities, especially in automotive applications, are represented by velocity magnitudes on a part of the HX front area and zero velocities on the remaining part. The innovative idea and the originality of the present study consists on dividing the water flow rates into various passageways as they reach a water-flow HX, where each passage is associated with several smaller HXs. In relation to the air flow, the smaller HXs are sequentially combined. The advantage of such splitting leads to keeping parts of the area of the initial HX from being subjected to low convection heat transfer with zero or negligible velocities and subsequently allows for an increase in the thermal performance globally. Moreover, the dividing idea enables faster but hotter airflow to be applied to each of the individual HXs. Computations for double-split HX utilizing a developed computational code are used to demonstrate the viability of this design. A traditional cross-flow water-air HX's thermal performance can be improved by up to 26.2 % using the novel idea, it has been demonstrated.

Calculation and Analysis of Motor Thermal Stress With or Without Eccentricity for In-Wheel Electric Vehicle Applications

The requirement of high-power density and the problems of high temperature and uneven air gap caused by environmental constraints make the alternating effect of internal temperature and related constraints between components during the operation of the motor for in-wheel electric vehicle. These effects and constraints will lead to thermal stress and concomitant deformation, and seriously affect the safe operation of in-wheel motors (IWMs) and vehicles. Aiming at the above problems, this paper takes a 15kW IWM as the research object. Based on the analysis of the mutual coupling relationship between the multi-physics field, such as the electromagnetic field, the temperature field, the flow field and the structural field, a thermal stress analysis model of the IWM is established and verified firstly. Then, quantitative calculation of the thermal stress/strain state of the IWM with or without eccentricity is carried out under different working conditions. The analytical results show that the thermal load generated internally leads to the generation of uneven thermal stress and accompanying thermal deformation, and the maximum thermal stress (MTS) and maximum thermal deformation (MTD) do not appear on the same component. Although eccentricity does not affect the position of the MTS and the MTD, it has an important effect on the maximum value of the stress and deformation, especially the eccentricity exceeds 30%. The results also demonstrate that the permanent magnet (PM) is most significantly affected by the eccentricity.

A Single-Phase Seven-Level Triple Boost Inverter for Grid-Connected Transformerless PV Applications

A new seven-level common ground (CG) switched capacitor (SC)-based grid tied transformerless inverter has been introduced in this paper, which has three times boosting capability of input voltage. Thus, this inverter is preferable for low voltage PV applications without any boost conversion stage. To step-up the input PV voltage and facilitate seven steps in output voltage, two SC cells are connected in parallel. A virtual dc link capacitor serves key role for negative half cycle on behalf of H-Bridge and helping in constructing topology with common ground. The common grounding configuration of this inverter helps in bypassing the stray capacitance, which eliminates the leakage current and consequently reduces EMI considerably. Hence, further no requirement of any electro-magnetic interference (EMI) filter for electro-magnetic compatibility (EMC). Additionally, this inverter handles reactive power during the grid's lagging/leading power factor (pf) condition. To regulate active and reactive grid power, a proportional resonant (PR) current controller is designed. The proposed modulation scheme helps in balancing capacitor's voltages at their base values with allowable ripple. A detailed comparison also has been presented with other contemporary seven level inverters. The inverter circuit details, control technique, PWM scheme, thermal modeling, and loss analysis with component design guidelines are described in detail. Experimental results are presented to validate the effectiveness and feasibility of this proposed inverter.

Thermal characteristics and distribution rule of lubrication film of full ceramic ball bearing under different service condition

PurposeThe study aims to the distribution rule of lubricating oil film of full ceramic ball bearing and improve its performance and life.Design/methodology/approachThe paper established an analysis model based on the fluid–solid conjugate heat transfer theory for full ceramic ball bearings. The distribution of flow, temperature and pressure field of bearings under variable working conditions is analyzed. Meanwhile, the mathematical model of elastohydrodynamic lubrication (EHL) of full ceramic ball bearings is established. The numerical analysis is used to study the influence of variable working conditions on the lubricant film thickness and pressure distribution of bearings. The temperature rise test of full ceramic ball bearing under oil lubrication was carried out to verify the correctness of simulation results.FindingsAs the speed increased, the oil volume fraction in full ceramic ball bearing decreased and the surface pressure of rolling element increased. The temperature rise of full ceramic ball bearings increases with increasing speed and load. The lubricant film thickness of full ceramic ball bearing is positively correlated with speed and negatively correlated with load. The pressure of lubricating film is positively correlated with speed and load. The test shows that the higher inner ring speed and radial load, the higher the steady-state temperature rise of full ceramic ball bearing. The test results are in high agreement with simulation results.Originality/valueBased on the fluid–solid conjugate heat transfer theory and combined with Reynolds equation, lubricating oil film thickness formula, viscosity temperature and viscosity pressure formula. The thermal analysis model and EHL mathematical model of ceramic ball bearings are established. The flow field, temperature field and pressure field distribution of the full ceramic ball bearing are determined. And the thickness and pressure distribution of lubricating oil film in the contact area of full ceramic ball bearing were determined.Peer reviewThe peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-05-2023-0126/

Modelling Air Cooling in a Module of Prismatic Li-Ion Cells

The control of temperature in lithium-ion stacks is of increasing industrial importance. In fact, an efficient thermal conditioning system ensures a homogeneous temperature distribution among the cells, preventing conditions which could hinder performance or led to temperature runaway and so a disruptive failure of the module. CFD models for thermal analysis can be useful in the design phase to optimize the module layout and to size the cooling system, as well as to support experimental campaigns in the definition of reduced-order thermal models to be implemented into the Battery Management System (BMS) for in-operation temperature prediction. The present work presents the development of a computational model of a 48V-20Ah 20-cell Li-ion module and its air-cooling system based on COMSOL Multiphysics software. Unlike most papers available in the literature, the individual cells are modelled by considering an internal ohmic heat generation term as a function of both state of charge, cell temperature and sign of the applied current (charge or discharge), exploiting experimentally validated data provided by the manufacturer in temperature-controlled conditions. In addition, the reversible thermal generation term due to entropic phenomena, which is often ignored in the literature, was computed alongside an irreversible term accounting for cell overpotentials. The entropic contribution, which was estimated experimentally and optimised computationally, resulted non-negligible when the module is cycled at ≤ 1C. To take into account the effect of the fan cooling system, the motion field was solved in COMSOL using a turbulent k-ε model. To ensure model accuracy, only minor geometrical simplifications were introduced to the fluid volume. The resulting geometrical complexity, made of manifold and narrow channels, called for special attention in the computational resolution. Assuming a decoupled behaviour, namely that the thermal evolution does not affect the flow field, allowed to use the stationary fluid-dynamic solution as the starting point for the time-dependent thermal simulation. The model was run under different experimental current profiles and the validation was performed on the entire module under effective operating conditions and not on a single cell under natural convection condition with the external environment, as is usually found in the literature. The computational data were found to be in good agreement with experimental measurements for all the cells even after charge-discharge cycles lasting more than two hours. The simulations provided insights to improve the positions of thermal sensors inside the module and to optimize the efficiency of the cooling system, that could not be done based on thermal measurements only. Figure 1

Analytical thermal resistance network model for calculating each mean die temperature of the multi-chips module combined with quad flat no-leads packaging

With the rapid advancement of next-generation communication technology, traditional Quad Flat No-leads (QFN) packaging is facing challenges to meet functional requirements. Due to its high integration and excellent thermal performance, the Multi-chips Module combined with Quad Flat No-leads (MCM-QFN) packaging is gaining popularity. However, the structural complexity of MCM-QFN packaging and the thermal coupling effect between multiple dies make it challenging to analyze the steady-state thermal distribution of MCM-QFN packaging, which is necessary for assessing the reliability and optimizing the layout design of the multi-chips module. By analyzing the heat dissipation path from each die to the ambient, this paper proposes an analytical thermal resistance network model for calculating each mean die temperature of MCM-QFN packaging. The thermal coupling effect among the multi-chips, the thermal spreading resistance between critical layers, and the boundary conditions and cooling conditions are all considered. All thermal resistances in the model are expressed analytically, and the mean temperature of each chip can be calculated within 0.1 s using MATLAB programming. To validate the accuracy of the proposed model, finite element method (FEM) simulations are conducted to provide a reference for the mean temperature of each chip under four sets of thermal conditions. The data comparison demonstrates that the analytical model is fast and accurate in calculating each mean die temperature of MCM-QFN packaging, with a maximum error of 3.72%, and the calculation speed increased by about 600× compared to that of FEM simulation. Furthermore, the analytical model is able to offer a direction for optimizing the layout design and material selection of MCM-QFN packaging.

Physical mechanisms and predictive performance of thermal conductivity models for nanofluids

Nanofluids present a promising group of fluids comprising base fluids like water, ethylene glycol, or oil, mixed with solid particles at the nanoscale. These nanofluids exhibit exceptional physical properties that hold significant potential for revolutionizing heat transfer processes. The objective of this study is to extensively investigate the phenomenon of improved thermal conductivity in nanofluids, focusing on critical factors such as particle volume concentration, size, temperature, and base fluid characteristics. Through a meticulous comparison of experimental data and analytical thermal conductivity models, the primary aim of this research is to uncover the underlying mechanisms responsible for this transformative effect. A comprehensive analysis of existing literature reveals a lack of agreement and conflicting findings regarding the influence of particle size, shape, and surfactants on thermal conductivity in nanofluids. Building upon this knowledge gap, our investigation aims to address and reconcile the observed discrepancies through a comprehensive parametric study. This comprehensive approach not only enhances our current understanding but also holds significant potential for optimizing nanofluids in various heat exchange applications. The importance of this study extends beyond the domain of nanofluid properties. By shedding light on the intricate physical mechanisms driving the enhancement of thermal conductivity, it has the potential to redefine the limits of heat transfer capabilities. The findings of this research hold great promise for engineers, researchers, and industries looking to fully exploit the potential of nanofluids. Through its rigorous methodology and unwavering dedication to unraveling the mysteries surrounding nanofluids, this study paves the way for groundbreaking advancements in the field of heat exchange.

Nonlocal strain gradient model for thermal buckling analysis of functionally graded nanobeams

Nonlocal strain gradient model for thermal buckling analysis of functionally graded nanobeams

Probabilistic machine learning aided transformer lifetime prediction framework for wind energy systems

Accurate lifetime prediction of transformers operated in power grids with renewable energy systems is a challenging task because it requires a large amount of data that is not usually available. In the case of wind energy, this complexity is intensified with the stochastic ageing process influenced by the intermittency of the wind and weather conditions. Existing models make use of detailed power topologies to evaluate transformer stress profiles and associated degradation. However, this modelling approach requires high computational resources and long simulation times. In this context, this paper presents a lifetime prediction model for transformers designed through probabilistic machine learning, thermal modelling and ageing analysis. The proposed model is compared with synthetic wind-to-power detailed simulations of a wind farm and validated with real data. The lifetime prediction is evaluated with different mission profile estimates and results show that the accuracy of the probabilistic machine learning model is very high, with an error of 0.47% for the median value and 80% prediction interval errors within 6%–7% with respect to observations. Moreover, there is a substantial reduction in the simulation time and memory requirements when compared to the synthetic model. A detailed sensitivity analysis demonstrates the influence on transformer ageing of different overloading strategies, thermal constants and the geographic location of the wind farm.

Investigation of desorption of hydrogen gas from polymer matrix using thermal desorption analysis and finite element modeling

Polymer materials are used widely as sealing materials and liners in hydrogen storage and transportation infrastructure. During operating conditions, polymers are exposed to high pressure hydrogen gas periodically. When in contact, the hydrogen gas diffuses through the polymer material with ease due to its smaller sized molecules compared to the polymer molecules. In the event of rapid decompression of outside hydrogen gas, the hydrogen molecules within the polymer diffuse out. This process is known as the desorption of polymer and can cause blisters or cracking causing permanent damage to the polymer. Here, we used a combined experimental and modeling approach to investigate the desorption of the hydrogen gas in the polymer. Thermal desorption analysis (TDA) experiments were performed on the polymer sample exposed to the high-pressure hydrogen gas to measure the diffusion coefficient and equilibrium hydrogen concentration. Experiments also provided the quantity of hydrogen within the polymer during the desorption process which followed Fick’s law. However, for higher pressurization values, some anomaly was observed in the quantity of hydrogen remaining in the polymer sample. A continuum mechanics based coupled diffusion–deformation-damage model was deployed to simulate the gas desorption process in the material using the finite element method to understand its effect on the material. It was found that the anomaly in TDA results were due to the blister formation on the polymer surface which resulted in longer hydrogen retention. Simulations also showed that blister formation can be affected by multiple parameters such as the addition of filler particles, and pre-existing cavity size.