Applied Chemical Engineering

Emerging Technologies in PCM-Driven Hybrid Cooling Strategies for Lithium-Ion Batteries

Dattatraya Subhedar

CHAMOS Matrusanstha Department of Mechanical Engineering, Chandubhai S Patel Institute of Technology, FTE CHARUSAT-Changa, 388421, India

Vijay chaudhari

Student, Gokul Global University, Opposite I.O.C. Depot, Near Sujanpur Patia, State Highway 41, Siddhpur – 384151, Gujarat, India

Pravin G Kulkarni

Department of Mechanical Engineering, PVG’s College of Engineering, Technology and Management, Pune, 411009, India

Naresh G Jaiswal

Department of Mechanical Engineering, PVG’s College of Engineering, Technology and Management, Pune, 411009, India

Ami R Barot

Department of Mechanical Engineering, PVG’s College of Engineering, Technology and Management, Pune, 411009, India

Kamlesh Chauhan

CHAMOS Matrusanstha Department of Mechanical Engineering, Chandubhai S Patel Institute of Technology, FTE CHARUSAT-Changa, 388421, India

Bhavin Mehta

CHAMOS Matrusanstha Department of Mechanical Engineering, Chandubhai S Patel Institute of Technology, FTE CHARUSAT-Changa, 388421, India

Abhishek Swarnkar

CHAMOS Matrusanstha Department of Mechanical Engineering, Chandubhai S Patel Institute of Technology, FTE CHARUSAT-Changa, 388421, India

Choon kit chan

Faculty of Engineering and Quantity Surveying, INTI International University, Nilai, 71800, Negeri Sembilan, Malaysia

Deekshant Varshney

Noida Institute of Engineering and Technology, 19, Knowledge Park-II, Institutional Area, Greater Noida (UP) -201324, India; Center for innovation and inclusive research, Sharda University, Greater Noida, 201310, Uttar Pradesh, India.

Saurav Dixit

Centre for Research Impact and Outcome, Chitkara University, Rajpura- 140417, Punjab, India; Department of Computers Techniques Engineering, College of Technical Engineering, The Islamic University, Najaf, 54001, Iraq

DOI: https://doi.org/10.59429/ace.v9i2.6058

Keywords: electrical vehicle; btms; pcm; process innovation

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Abstract

Global demand of electric vehicles and high-energy-density lithium-ion batteries has created a critical need for efficient battery thermal management systems (BTMS) capable to controlling battery cell temperatures between 20–40 °C and prevent the thermal run away in battery packs. The choice of phase change material (PCM)-based cooling has increased as passive technique that manage excess battery heat gained by absorbing and storing as latent heat without any external power. Despite their advantages, the low thermal conductivity of conventional PCMs (around 0.2–0.5 W m⁻¹ K⁻¹) restricts their capability to effectively remove heat during charging and discharging with high C-rate. To mitigate this limitation, current research has focused on hybrid PCM-based BTMS, where PCMs are combined with liquid cooling channels, heat pipes, metal foams, thermal fins, or nano-enhanced PCMs (NePCMs) to enhance heat transfer. Reported research studies suggest that such hybrid systems can lower the peak temperature by 10–25 °C and improve temperature uniformity by 30–60 % compared with conventional cooling approaches. In upcoming years, among the various BTMS investigated, the combination of PCM with liquid cooling or heat pipe technologies, along with high-conductivity enhancements shows strong potential for electric vehicle battery packs. This article provides a detailed assessment of BTMS using PCM and hybrid PCM-based systems. In addition, use of Machine learning, digital twin structures, and advanced optimization techniques for predictive Battery thermal management are also discussed.

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