Metallic PCM-based battery thermal management system for fast charging/discharging applications

Fast charging technology is critical for increasing user convenience and promoting the wider adoption of electric vehicles (EVs), but it also poses significant thermal issues that require effective temperature management systems. This article proposes a new battery thermal management system (BTMS) based on metallic phase-change materials (MPCMs) and liquid mini-channels. The BTMS aims to address the challenges of fast charging/discharging of lithium-ion batteries (LIBs), which can generate excessive heat and degrade battery performance and safety. The BTMS incorporates gallium as the MPCM and water as the coolant and employs a hybrid cooling strategy combining latent heat storage and liquid convection. The design, simulation, and experimental validation of the BTMS are presented in this article. The BTMS demonstrates advantages over conventional PCMs in terms of thermal conductivity, heat dissipation, and system weight. Various design parameters, such as MPCM thickness, channel number, and mass flow rate, are investigated for their effects on the thermal performance and efficiency of the BTMS. The proposed BTMS effectively controls battery temperature, enhances heat transfer, and reduces system weight compared to other PCM-based BTMS. It shows promising potential for applications that require fast charging/discharging capabilities. © 2024 Elsevier Ltd