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Electric mobility decarbonizes the transportation sector and effectively addresses sustainable development goals. A good battery thermal management system (BTMS) is essential for the safe working of electric vehicles with lithium‐ion batteries (LIBs) to address thermal runaway and associated catastrophic hazards effectively. However, PCMs suffer from low thermal conductivity issues, and hence, enhancement techniques include the use of fins, nano‐additives, extended graphite powder, and so forth. The use of composite phase change materials effectively addresses LIB thermal management widely used in electric vehicles while mitigating thermal runaway, besides providing flame retardancy, thermal/mechanical stability, and electrical insulation, and preventing leakage. It is noted that no single strategy of BTMS is brought down to a safe zone of temperature, and hybrid BTMSs are being employed, invariably involve phase change materials (PCMs) to a large extent. It is essential to utilize CPCMs to address the effects of low‐temperature environments and vibrations considering vehicle driving cycles and operating conditions. It is observed from the review that ultrasonic monitoring and early detection of internal short circuits are the steps towards mitigation of thermal runaway propagation. It is required to utilize optimization methods, machine learning and IoT tools for a feasible PCM based BTMS work. Present review briefly describes potential methods for effective utilization of PCMs, comparison among different methods, challenges associated and potential solutions. It is highly essential to develop compact and economical BTMS with effective CPCMs for better and safer LIB operation to attract large‐scale commercialization of electric vehicles. [ABSTRACT FROM AUTHOR]

Lithium battery temperatures will increase if the heat produced during the charging and discharging procedures is not promptly vented externally. Fewer investigations have been conducted on materials that can retain good flexibility at room temperature and shape stability at high temperatures under the existing thermal management system for phase change materials (PCM). In this study, a particular kind of flexible composite PCM (CPCM) at room temperature is created to address the issue of heat transfer between the PCM and the power battery. The characteristics of hardness, room-temperature flexibility, form stability at high temperature, and thermal conductivity are compared with those of three other thermally induced flexible CPCMs. The flexibility at room temperature of the new CPCM is demonstrated by the results, which makes assembly easier and helps further lower the contact thermal resistance. Charge–discharge test comparisons of the battery modules employing the chosen CPCM and thermally induced CPCM are performed to further evaluate their thermal management capabilities. The thermally induced CPCM exhibits larger maximum temperature profiles at the discharge rates of 1C, 2C, and 3C than the room-temperature flexible CPCM. The variations in maximum temperatures are 0.96, 1.48, and 2.08 °C. [ABSTRACT FROM AUTHOR]

The existing conventional vehicle transportation landscape in India is grappling with challenges stemming from extensive air pollution, health risks, surging oil prices, limited fossil fuel resources, substantial oil import expenses and energy volatility. To counter these issues, Electric Vehicles (EVs) are progressively replacing internal combustion engines, offering a promising route toward decarbonization and mitigating climate concerns. EVs rely on electric motors powered by batteries, predominantly Lithium-ion batteries (LIBs), known for their superior attributes such as low self-discharge, high energy density and extended life cycle. Nevertheless, LIB performance is significantly influenced by operating temperatures, with suboptimal conditions leading to decreased efficiency, power loss and faster aging. Addressing this, an effective Battery Thermal Management System (BTMS) becomes crucial to maintain batteries at optimal temperatures, enhancing their efficiency and safety. This study focuses on a computational analysis of passive heating systems employing Fins and Phase Change Materials (PCM) for 18650 Li-ion battery thermal management at low temperatures, with specific attention to battery module analysis. Numerical analysis using ANSYS FLUENT investigates the influence of varying PCM thickness on heat transfer, predicting temperature distribution and discussing its impact on battery output performance. [ABSTRACT FROM AUTHOR]

Battery thermal management system (BTMS) may seem a very standard term, but it is the lifeline of an efficient battery pack module in various vehicles and standalone stationary energy storage systems. The majority of the available literature is aimed toward temperature optimization of batteries in hotter climatic conditions. The cold temperature‐related effects on battery packs have amplifying implications on the battery cycle life and operational capacity. The electric vehicles operating in cold temperature environment face sudden fluctuations in temperatures across the battery pack module due to large temperature gradient between battery surface and internals, and ambient conditions. This work focuses on addressing the problem related to sudden drop in cell temperatures when battery operations are switched off (cold stop conditions). The phase change materials (PCMs) based passive BTMS system is evaluated in this study. The BTMS with different designs and PCMs are modeled in Multiphysics environment and simulated close to extreme cold temperature environments. The formulated models are then used for comparing commercially available PCMs material for their efficiency and viability. The main parameter evaluated was rate of temperature decrease, it was observed that organic mixture‐type PCMs are best suited for cold temperature application. [ABSTRACT FROM AUTHOR]

Because of their high energy capacity and power density, lithium‐ion batteries are an essential component of electric and hybrid vehicles; however, they frequently experience excessive temperature rise because of heat creation inside the batteries. The charge state and charge/discharge rate play a major role in this heat generation. Due to its high latent heat, compact design and lightweight nature without requiring any external power, passive techniques like phase change material (PCM) and heat pipe (HP) cooling have gained widespread popularity. Therefore, this work focussed on hybrid BTMS integrating Heat Pipe with PCM for better thermal management of battery pack supported by a heat pipe that is used to analyse the thermal performance of a battery module having three and four lithium‐ion batteries placed in series and parallel. The objective of maintaining temperature gradient of less than 5°C between the adjacent cells and maintaining the overall battery temperature in the range of 25°C–45°C has been successfully achieved. The results of experiments at various discharge rates showed that a heat pipe was crucial to quickly transferring heat and maintaining temperature homogeneity for PCM‐based battery modules. It can be concluded that the data presented above can offer views for creating and improving battery heat management systems. [ABSTRACT FROM AUTHOR]

To address the bottleneck of easy leakage and low thermal conductivity of phase change materials (PCMs) for battery thermal management. Phase change composite (PCCs) with paraffin (PA) as the PCM, styrene ethylene butylene styrene (SEBS) as the supporting skeleton, and boron nitride (BN) as the thermally conductive filler were fabricated by the sacrificial template method. Compared with the composite prepared by melt-blending method, the thermal conductivity of PCC was improved by 27.6 % and the leakage rate was reduced by 82.4 % because the BN was rubbed with Na 2 SO 4 under the shear provided by internal mixer. As a result, the maximum temperature and maximum temperature difference of the battery pack with PCC cooling were 35.8 % and 62.5 % lower than those without PCC cooling at 2C discharge rate. In total, this work offers a strategy for improving the thermal conductivity and the leakage-proof ability of PCCs as well as for large-scale fabrication. [Display omitted] • The SEBS-BN@PA composites are prepared by the sacrificial template method. • The prepared composites have good leakage-proof ability and shape stability. • The composite has higher thermal conductivity than those prepared by melt-mixing method. • The composite presents excellent performances for battery thermal management. [ABSTRACT FROM AUTHOR]

Thermal management is a crucial parameter in lithium-ion batteries to maintain the temperature of the batteries within safer working limits. If the optimum working temperature is not maintained, it triggers thermal runaway conditions and causes them to propagate heat from one cell to another within pack level configurations. In battery thermal packaging, several government norms such as GB 38031/32 has suggested that for optimum thermal packaging, there should be a significant delay in the thermal runaway trigger point which can prevent a vehicle from going into catastrophic failure since the driver gets a preventive alert for the high-rise temperature of a cell at an early stage. Delaying thermal runaway occurrence can be effectively achieved by using an integrated layer of PCM. However, present conventional PCMs have a lower thermal conductivity which poses instability in delaying thermal runaway trigger point. This can be improved by using graphene-enhanced composite phase change material, in which the percentage of added extended graphene (EG) determines the improvement in thermophysical property, concisely thermal conductivity of CPCM. The current study examines thermal runaway in widely used cathode materials, LiNiMnCoO 2 (NMC) and LiFePO 4 (LFP), within a typical large format prismatic cell profile with a commonly used heater-assisted test. The thermal runaway trigger point is monitored for the cases of cell without CPCM and with CPCM to find potential improvement in the delay point. Thermal runaway modeling and statistical safety regime response show that submerging batteries in a CPCM can delay thermal runaway onset by 20 min. When scaling up to a 7S1P battery module level, it is concluded that the smallest addition of EG in CPCM can delay the thermal runaway trigger point and reduce peak temperatures in the battery module over 66 to 113.2 min, which strategically complies with battery safety norms. • The safety regime response of Li-Ion cell is investigated for different cathodic chemistry. • A comprehensive validated four equation battery thermal abuse model is developed. • Thermal behavior of battery with varying composite phase change material thermal conductivity is investigated. • A novel statistical approach is shown to find the most effective TMS parameter. [ABSTRACT FROM AUTHOR]

In order to ensure the safety and stability of the cooling system during the operation of the battery thermal management system combined with composite phase change material cooling and liquid cooling, it is usually necessary to continuously pump cooling water. It inevitably caused that the latent heat of composite phase change material could not be fully released and extra pump power was consumed. In the study, five different energy saving strategies were proposed and the energy efficiency ratio was defined to evaluate their cooling effects and energy saving. The effect of energy saving strategies on energy consumption of liquid cooling and latent heat utilization of composite phase change material was analyzed. The results show that III and V can meet their cooling requirements and have a high energy efficiency ratio. The screw pitch and cooling water flow rate in these two modes were investigated. The results show that the increase in screw pitch reduces the heat transfer efficiency, resulting in an increase in T max and Δ T max , and Δ T max exceeding the maximum range. Diminishing the cooling water flow will precipitate a rise in battery temperature, enabling the CPCM to operate at its maximum capacity and consequently decreasing Δ T max. As a cooling water flow of 20 ml/min in III and V all can satisfy the cooling requirements. Additionally, the III was also competent when the cooling water temperature was raised from 25 °C to 35 °C. [ABSTRACT FROM AUTHOR]

PV/T is designed to convert solar radiation into electricity energy; however, as the temperature rises, their efficiency decreases. This study evaluates experimentally and numerically the performance of PV/T systems. Two cooling methods were used: air jets for enhanced heat transfer and phase change material (PCM) as an energy storage source. Four cases were compared: case A (with PCM and jet), case B (with PCM, without jet), case C (without PCM, with jet), and case D (no cooling). The results were validated by experimental measurements under a solar simulator and the comparison between the experimental and numerical results is satisfactory. The findings show that case A (with PCM and jet) reduced the PV temperature by 21 °C and improved the electrical efficiency by 7.2 % compared with case D (no cooling). The highest electric and thermal efficiency of the PV/T system reached were 12.94 % and 79.1 % respectively at higher air flow rates in case A (with PCM and jet). The novelty of present study is the combination of jet impingement and phase change material, which can provide high electric and thermal efficiencies and allows 2 h' work after sunset. [ABSTRACT FROM AUTHOR]

Phase change energy storage materials are promising for addressing issues such as energy distribution imbalance and mismatched supply and demand. However, practical application of phase change materials (PCMs) is hindered by challenges like crystalline rigidity, leakage, and poor thermal conductivity. This study introduces a novel form-stable composite phase change material (CPCM) with high thermal conductivity and flexibility, prepared through solution blending. The CPCM exhibits not only a high phase change enthalpy but also shape stability and thermal stability. By uniformly dispersing lauric acid (LA) -modified carbon nanotubes-COOH (CNTs-COOH) in the CPCM, its thermal conductivity is significantly improved. Even with just 1% CNTs-COOH, the thermal conductivity of the CPCM is 2.4 times that of the original. Moreover, the composite material demonstrates excellent thermal management performance for high-temperature lithium-ion (Li-ion) batteries. These findings open up new possibilities for developing environmentally friendly and highly thermally conductive flexible CPCM materials. [Display omitted] • SEBS-based thermally induced flexible CPCM is proposed. • The CPCM exhibit high latent heat of 150.9 J/g and excellent thermal stability. • The use of LA to modify CNTs-COOH improved the thermal conductivity of CPCM. • CPCM exhibit an excellent battery thermal management effect at high temperature. [ABSTRACT FROM AUTHOR]

In this work, a composite cooling system including composite phase change material(CPCM) and liquid cooling is designed for battery pack, and the effects of coolant flow rate, battery spacing, thermal conductivity of CPCM, channel number of cooling plate on the safety performance of battery pack under thermal runaway propagation are studied. The results reveal that: (1)Coolant flow rate increase mainly delays the thermal runaway propagation on both sides of cooling plate. When the coolant flow rate is 0.029 m/s, the thermal runaway propagation time through the cooling plate is 32.9s, which is extended by 1.84 times than that at 0.009 m/s (2)Battery spacing increase delays thermal runaway propagation and changes the propagation path. (3)Thermal conductivity reduction of CPCM can significantly delay thermal runaway propagation, because the heat is concentrated in the periphery of the battery and is hard to transfer though CPCM and cooling plate. (4)Compared with other influence factors, channel number of cooling plate has less influence on the overall thermal runaway propagation time. When the channel number is between 5 and 1, the total thermal runaway time changes within 25.5s–27s. The conclusions in this work are helpful to design a safer thermal management system for lithium-ion battery packs. • A novel composite cooling strategy is designed for cylindrical battery pack. • Effects of different factors on the thermal safety of the battery pack are studied. • Thermal runaway propagation path and time of the battery pack are analyzed and obtained. [ABSTRACT FROM AUTHOR]

The introduction of a high-thermal-conductivity porous medium stands as an effective strategy for enhancing the heat transfer rate within battery thermal management using phase change material (PCM). In this study, we have delved into the investigation of heat transfer augmentation in battery thermal management through the implementation of toroidal porous medium. The exploration encompasses the effects of Rayleigh numbers, thicknesses of the toroidal porous medium, different kinds of porous medium and PCM. By comparing the liquid fraction, dynamic temperature and the latent heat ratio, we found the effect of Rayleigh number and thickness of porous medium on the property of the battery thermal management. The results indicate that by applying thicker toroidal porous medium could weaken the heat accumulation derived by high Rayleigh numbers. Case of d = 0.273R exhibits superior performance for a significant portion of the entire process compared to other cases with thickness of 0.235R, 0.326R, 0.408R and uniform distributed, while the dominant position is difficult to hold due to the heat accumulation. The conclusion is universal for different porous medium and PCM materials. The optimal distribution of porous medium should seek a balance between enhancing heat conduction and weakening thermal convection. A more scattered distributed porous medium could weaken the effect of heat convection and rises the latent heat ratio. [ABSTRACT FROM AUTHOR]

The use of a hybrid cooling system, which combines phase change material (PCM) and liquid channels, has been extensively researched to mitigate the risk of battery thermal runaway. However, the existing studies on hybrid cooling systems have overlooked the impact of buoyancy-driven natural convection in PCM. This results in a uniform flow rate allocation among liquid channels, leading to inadequate heat dissipation performance. To this end, this paper proposed a prediction-informed adaptive flow rate allocation strategy for the hybrid cooling system considering natural convection in PCM. First, a novel thermal runaway model was developed, followed by a PCM model that considers natural convection. Then, the proposed strategy utilized Bi-directional Long Short-Term Memory (Bi-LSTM) to predict the outlet temperature, which represents the cooling demand. The flow rate was regulated based on the predicted temperature to avoid an initial flow rate of 0 in the liquid channel and achieve a timely response. The results showed that the proposed strategy extended the thermal runaway propagation interval by 60.6% (85.9 s) and reduced the total flow rate by 31.7%. This strategy significantly enhanced the hybrid cooling system's performance, without increasing the parasitic energy or reducing the battery pack's energy density. • Prediction-informed strategy to enhance hybrid cooling systems' performance. • Adaptive flow rate regulation for hybrid cooling systems considering natural convection. • Novel coupled electrochemical–thermal model for thermal runaway analysis. [ABSTRACT FROM AUTHOR]

Polyethylene glycol (PEG) is a commonly used phase change material for thermal energy storage. It can store amounts of heat in the process of phase transition, whereas the solid-to-liquid transition requires it to be form-stabilized before application. In this study, a phase change composite with form-stability and processibility is prepared by simply blending PLA with PEG at 180 °C, reaching a maximum PEG loading of 90 wt%. The preparation is easy, cheap, environmental-benign, and scalable. Besides, the obtained PLA/PEG (PLEG) composites are feasible for regulating the thermal behaviors of batteries operated at high rates, providing a low-cost and simple approach to improving the cyclability of fast-charging batteries. [Display omitted] • The method of preparing PLEG by blending and heating PLA and PEG is simple and low-cost. • The prepared PLEG possesses considerable latent heat storage capacity, formability, shape-stability, and reusability. • PLEG is appliable for the thermal management of lithium-ion batteries operating at high rates. [ABSTRACT FROM AUTHOR]

• Developed and analyzed a novel hybrid battery pack thermal management system. • Incorporated a novel three-stage cooling strategy into the thermal management system. • Latent heat of PCM effectively extracts heat from the cylindrical Li-ion cells. • Secondary coolants increase the overall heat transfer coefficient of PCM. This paper introduces a novel hybrid thermal management concept, which use secondary coolants (air and water) to extract heat from a phase change material (paraffin), resulting in increased heat extraction capability of the paraffin and improvement the overall thermal performance of the battery module. This concept was analyzed using experimental and numerical studies. The experimental studies were conducted to obtain the temperature and heat flux profiles of the battery module. The numerical model is developed and validated using the experimental data obtained. The outcome of the study showed that the battery module temperature reached the phase change temperature threshold of the PCM in the fifth discharge cycle, and the through the use of latent heat the battery module temperature was maintained between 42 and 44 °C. Additionally, the thermal uniformity started to increase once the PCM started to change and the PCM utilization was ∼2.3 % after seven discharge cycles. Therefore, the proposed thermal management concept for the battery module can sustain the thermal environment needed for effective operation of the Lithium-ion batteries. [ABSTRACT FROM AUTHOR]

While active thermal managements for Li-ion battery (LIB) consume a large amount of energy, passive one based on phase change material (PCM) fails to release thermal energy for heating as required. Thus, intelligent heat storage and release is urgently needed for utilizing PCM as passive thermal management. Herein, porous boron nitride/polyvinyl alcohol (BN/PVA) skeleton with highly ordered microchannels was fabricated to impregnate hydrate salt sodium acetate trihydrate (SAT) solution forming shape-stable SAT@BN/PVA composite with efficient thermal energy storage performance. Disturbance from magnetic trigger in the hydrate salt composite microchannels promotes nucleation and solidification, thus initiates heat release as required and remotely. Meanwhile, anisotropic heat transfer from the highly ordered microchannels can effectively enhance heat release velocity and efficiency. The magnetic triggered process is studied theoretically and experimentally, and optimized to release heat in 25 s with efficiency up to 99%. Consequently, heat release can improve temperature by 10 °C when battery pack stops working at −20 °C and enhance discharge capacity by 75% during cold-start. This research provides a new method for intelligent thermal management of LIB working in cold environment. [ABSTRACT FROM AUTHOR]

• High-stable CPCM for battery thermal management is prepared via one-pot strategy. • 3D nano-framework is in-situ constructed to obtain high shape stability of CPCM. • Nano-framework stacks into a developed mesoporous structure to suppress leakage. • The obtained CPCM shows outstanding cooling performance for the battery module. • No leakage trace is detected on the battery module during accelerated aging tests. Mainstream phase change material (PCM) for the thermal management of battery modules has been suffering from the leakage issue due to the weak capillary condensation from its micron-scaled polymer framework. Therefore, in this work, we design a high-stable and leakage-proof composite PCM (CPCM) by in-situ constructing a nano-scaled resorcinol-furfural polymer framework (RF-PF) in PCM via a one-pot strategy. Compared to classical micron-scaled framework of epoxy resin, the nano-scaled RF-PF stacks into a three-dimensionally mesoporous structure, and thus provides a much more intensive adsorbability towards PCM to prevent leakage. The mass retention rate of the RF-PF-based CPCM (RF-CPCM) during the leakage tests is up to 99.84 wt%. Combining with the suitable thermo-physical properties including a phase change enthalpy of 107.18 J g−1, phase change temperature region of 40– ∼ 55 °C and thermal conductivity of 1.58 W m−1 K−1, the RF-CPCM demonstrates effective and stable thermal management performances towards the pouch and cylindrical battery modules. For example, the temperature of the pouch battery module can be controlled below 41.15, 44.16 and 46.82 °C during 0.5-C, 1-C and 2-C discharges, respectively. During the accelerated aging test, the leakage trace appearing on the traditional CPCM module, is effectively overcome in the RF-CPCM module. [ABSTRACT FROM AUTHOR]

The era of electric mobility has started, and petrol/diesel vehicles are being replaced by electric vehicles (EVs). The phase change material (PCM) is a trending field of research in its application of energy storage and thermal management. PCM-based thermal management method is found to be quite simple and effective for battery packs. However, its commercialization is difficult due to its low thermal conductivity and extra weight addition to the battery pack. Hence, the present research focuses on the battery performance with PCM. The experimental setup for a 48V, 25Ah battery pack is developed, and its performance is explored with and without PCM. The numerical model for same sized battery pack is developed, and validated with experimental results. The major objective of the present research is to find the optimal gap between two battery cells so that a sufficient amount of PCM can be filled inside the battery pack. Initially, inline and staggered cell arrangements are examined, and no significant difference in thermal performance is found. Further, cell spacing of 5 mm, 3 mm, and 1 mm are examined, and maximum temperature and temperature difference are compared along with the weight and volume of the battery pack. For a single charging process, 1 mm cell spacing is found sufficient, considering the weight of the battery pack and thermal performance. However, with 1 mm cell spacing, temperature increases significantly after each charging and discharging. At the same time, 3 mm and 5 mm are found as feasible solutions considering single and double charging-discharging cycles, respectively. 3 mm cell spacing is better option when weight is a critical issue, while 5 mm cell spacing is better when thermal performance is a critical issue. The current study offers guidance in the advancement of battery packs, particularly in cases where space constraints are a concern. • The research focuses on utilization of optimal amount of PCM. • The battery charging experiments are carried out on 48V, 25Ah battery pack. • PCM OM42 reduced battery temperature by 18 %. • The inline and staggered arrangements are found equally effective. • 3 mm cell spacing is found sufficient with limited weight increment. [ABSTRACT FROM AUTHOR]

Lithium-ion batteries are the most commonly used battery type in commercial electric vehicles due to their high energy densities and ability to be repeatedly charged and discharged over many cycles. In order to maximize the efficiency of a li-ion battery pack, a stable temperature range between 15 °C to 35 °C must be maintained. As such, a reliable and robust battery thermal management system is needed to dissipate heat and regulate the li-ion battery pack's temperature. This paper reviews how heat is generated across a li-ion cell as well as the current research work being done on the four main battery thermal management types which include air-cooled, liquid-cooled, phase change material based and thermo-electric based systems. Additionally, the strengths and weaknesses of each battery thermal management type is reviewed in this study. It was determined that air cooled systems are suited for short-distance travel electric vehicles, liquid cooled are for electric vehicles that require long-distance travel, larger battery packs and for high thermal loads, phase change material based are for electric vehicles with constant thermal loads and stable ambient temperatures and thermo-electric battery thermal management systems are best best suited in conjunction with the other types for better control. • Present simplified heat generation model for li-Ion batteries. • Review of upcoming PCM Cooling BMS models. • Analysis of strengths and weaknesses of air, liquid, PCM, and thermoelectric BMS. • Recommendation on appropriate BTMS type for different EV models. • Identified main attributes required for an effective BMS for EV systems. [ABSTRACT FROM AUTHOR]

The safe and efficient power battery thermal management system (BTMS) is a prerequisite for the effectiveness and long service life of electric vehicles. So, a BTMS with inserted multi-layer phase change materials (PCMs) is proposed to enhance the safety and working performance of battery pack. Effects of PCM settings and operating conditions on the thermal performance of battery pack are discussed and analyzed. The results reveal that PCM cooling plays a significant role in the thermal management of battery pack, where the maximum temperature value and temperature difference of BTMS with multi-layer PCM #C are respectively reduced by 13.61 °C and 2.54 °C compared to battery pack without PCM. Besides, the coupling effects of multiple factors, that is, PCM permutation, the thickness and height of PCMs, and ambient temperature, on the heat dissipation of battery pack are discussed via orthogonal results analysis. The optimized multi-layer PCMs are obtained for the BTMS, i.e., P s = 121, h 1 = 5 mm and L = 6 mm, which achieves the lowest values of T max = 43.02 °C and Δ T = 3.37 °C at T amb = 20 °C. It provides insights for optimizing thermal control strategies for the advancement of thermal management in electric vehicles, ultimately enhancing safety, performance, and longevity. • A battery thermal management system with multi-layer phase change materials is proposed. • Multifactorial effects of phase change materials on the thermal performance are discussed. • Orthogonal results analysis is employed to gain the optimized thermal management systemt setting. • Thermal performance of battery pack is strongly improved. [ABSTRACT FROM AUTHOR]

The phase change immigration of flame retardant Composite Phase Change Material (CPCM), especially the temperature aging effect during multicycle process, greatly restricted its application in power battery pack of electric vehicle and energy storage system. In this study, the properties of flexible flame-retardant CPCMs before and after temperature aging were investigated, and the battery thermal management effects of battery modules were compared. The results revealed that flexible CPCMs with styrene block copolymers exhibited little volume change owing to their elastic and anti-leakage properties, effectively alleviating flow and agglomeration. In addition, battery modules with flexible flame-retardant CPCMs exhibited prominent battery thermal management. These mechanisms in flame-retardant CPCMs can profoundly affect the design and preparation of multifunction CPCMs, providing novel insights into passive thermal management of battery systems. [ABSTRACT FROM AUTHOR]

The phase change immigration of flame retardant Composite Phase Change Material (CPCM), especially the temperature aging effect during multicycle process, greatly restricted its application in power battery pack of electric vehicle and energy storage system. In this study, the properties of flexible flame-retardant CPCMs before and after temperature aging were investigated, and the battery thermal management effects of battery modules were compared. The results revealed that flexible CPCMs with styrene block copolymers exhibited little volume change owing to their elastic and anti-leakage properties, effectively alleviating flow and agglomeration. In addition, battery modules with flexible flame-retardant CPCMs exhibited prominent battery thermal management. These mechanisms in flame-retardant CPCMs can profoundly affect the design and preparation of multifunction CPCMs, providing novel insights into passive thermal management of battery systems. [ABSTRACT FROM AUTHOR]

A battery thermal management system (BTMS) using a composite phase change material (CPCM) is proposed for both heat dissipation under fast charging conditions and preheating in low temperature environments. Based on the validated battery thermal model and CPCM model, a parametric study was performed to determine the optimal conditions. As a result, in the proposed concept, the highest maximum temperature and maximum temperature difference are 39.3 °C and 3 °C under 3C charging conditions at room temperature. This is achieved by decreasing the total operating time of the liquid cooling system by 35.2% compared to that of the conventional BTMS, and after the cycle, the latent heat is fully recovered for use in a continuous cycle. Also, under low temperature conditions of −10 °C, the final maximum temperature is 29.2 °C after preheating in the proposed BTMS. The temperature difference is 2.5 °C, which is significantly lower than when applying the existing liquid heating method. Therefore, the proposed BTMS is advantageous in terms of both the cooling performance under fast charging conditions and preheating under low temperature conditions. • A compact BTMS with composite phase change material using copper foam is proposed. • Both the extreme conditions of fast charging and low temperature are covered. • The practical application of CPCM under charge-discharge cycle is considered. • Battery thermal model and CPCM model were validated well with experimental data. [ABSTRACT FROM AUTHOR]

A hybrid BTMS considering heat dissipation and mechanical protection for prismatic battery modules is constructed, which combines the modularized liquid-cooling plate (MLCP) and the phase change material (PCM)-negative Poisson's ratio structural laminboard. The effects of interior structure, flow direction, flow rate, and cooling strategy of the MLCP on the thermal performance of the battery module were investigated. It showed that the proposed MLCP was able to weaken the heating effect of coolant along the flow path by more than 50 % through modularized design. Furthermore, the alternating cooling strategy of sub-domains of MLCP was designed, which halved the energy consumption of liquid cooling systems. In comparison to the case without the laminboard, the maximum temperature and temperature difference of the case with it were reduced by 3.79 °C and 2.50 °C, respectively. Meanwhile, the maximum stress and total deformation of the battery cell were also decreased by 1.67 MPa and 78.1 μm with the protection of the laminboard at 1000 N. With the MLCP and the multifunctional laminboard, the maximum temperature and temperature difference of the battery module were kept below 35 °C and 4 °C, respectively, even at a high discharge current of 100 A and under dynamic conditions. [Display omitted] • Thermal, mechanical, lightweight, and energy-saving designs are considered in BTMS. • Modularized liquid-cooling plate is designed to improve temperature inconsistency. • A novel laminboard is proposed combining negative Poisson's ratio structure and PCM. • Alternating and delaying cooling strategies can both save energy consumption of BTMS. [ABSTRACT FROM AUTHOR]

With the implementation of zero carbon strategy, electric ships based on lithium-ion power batteries have become development mainstream. Compared with vehicle power batteries, the heat generated by the larger size of ship power batteries is more difficult to be discharged. Therefore, efficient ship power battery thermal management (BTM) systems are urgently needed. Herein, a pipeless cooling system based on shape-stabilized phase change materials (SSPCM) as the seawater channel was proposed and experimentally studied. Firstly, the excellent seawater corrosion resistance of SSPCM channel was proven. Then, the cooling performance of SSPCM channel was compared with the metal channel and SSPCM coupled with metal channel. The results demonstrated that the maximum temperature and maximum temperature difference of the SSPCM channel system were 8.3 °C lower and 1.1 °C lower, respectively than the metal channel system. Although the cooling performance of SSPCM and SSPCM coupled with metal channel was similar, SSPCM had a lighter weight and avoided seawater corrosion. Furthermore, the effects of different factors on the SSPCM channel system were investigated and the key factors were identified by orthogonal experiment. The innovative use of SSPCM channel and seawater provides a new idea for the cooling of the ship power batteries. [Display omitted] • A pipeless cooling system based on SSPCM as the seawater channel was constructed. • The excellent seawater corrosion resistance of SSPCM channel was proven. • The performance of power battery with three channels was compared. • Key factors were analyzed based on orthogonal experiment. [ABSTRACT FROM AUTHOR]

• Form-stable and flame-retardant CPCM is produced for battery thermal safety management. • The optimum mass ratio of the CPCM is obtained by comprehensive analysis. • CPCM has a positive effect on battery heat absorption and increasing the time between the thermal runaway spread. Phase change materials (PCMs), characterized by zero energy consumption and high energy storage density capability, have a wide range of applications. However, the development of organic PCM is restricted by their low thermal conductivity, easy leakage and high combustibility. In this study, we produced a composite phase change materials (CPCM) with both high thermal conductivity and flame-retardant effect for application in battery thermal safety management. We demonstrated that addition of a porous network structure of EG as a shaping support to increase PA's thermal conductivity, and incorporation of environmentally safe and non-toxic silica-based flame retardant (SiO 2 sol) improved the flame retardant properties. The optimum mass ratio of the CPCM was obtained by comprehensive analysis of the shape and thermal stability, energy storage performance and thermal conductivity. It was also verified by cone calorimetry that the CPCM outperformed pure PA in several aspects: heat release, smoke release rate and emission of toxic gases. The cooling and thermal runaway experiment of the battery module showed that the addition of CPCM had a positive effect on absorption of battery heat and extending the time between the thermal runaway spread of battery modules (21 s increasing to 396 s), providing valuable time for the safe evacuation of people in the event of a runaway fire. [ABSTRACT FROM AUTHOR]

Lithium-ion batteries (LIBs) are frequently employed in electric vehicles for their high energy density and lengthy cycle life. However, efficient battery thermal management system (BTMS) is critical for ensuring the reliability, safety, and service life, as temperature greatly impacts their performance. The potential risks of battery fire and explosion under excessive temperatures necessitate the development of effective emergency management and technologies to maintain safe operation. Phase change material (PCM) which offers distinct advantages, including reasonable cost, low energy consumption, and excellent temperature uniformity, making it an attractive candidate for thermal management, has emerged as a promising solution for BTMS. This comprehensive review aims to shed light on PCM-based BTMS, and it is found that carbon-based additives are better than metal-based additives concerning density and stability, and the addition of polymers and nanomaterials can improve the structural stability and mechanical properties. However, the flammability of PCM exacerbates the fire risk and hazard of battery thermal runaway (TR), and this review also has a particular emphasis on enhancing PCM's flame retardant properties and exploring its applications in BTMS. Flame-retardant PCM can ensure the safety of LIB utilization process and has a promising application in suppressing TR. Moreover, there exists a prominent challenge of the comprehensive need for optimization of heat dissipation optimization and improvement of TR propagation suppression ability of PCM-based BTMS. Finally, the challenges and outlooks focus on the future PCM-based BTMS are disclosed, in the hope of bring new insights to building a synergistic BTMS. Graphic abstract [Display omitted] • Heat dissipation optimization and thermal runaway propagation suppression coordination. • Highly thermally conductive, non-leakage deformable, flame retardant PCM compared. • Feasibility to utilize PCM to prevent the propagation of thermal runaway proposed. • Insights into research gap and further development and of PCM provided. [ABSTRACT FROM AUTHOR]

In this work, a novel battery thermal management system (BTMS) integrated with thermoelectric coolers (TECs) and phase change materials (PCMs) is developed to ensure the temperature working environment of batteries, where a fin framework is adopted to enhance the heat transfer. By establishing a transient thermal-electric-fluid multi-physics field numerical model, the thermal performance of the BTMS is thoroughly examined in two cases. The findings demonstrate that increasing the TEC input current, fin length, and thickness is beneficial for reducing the maximum temperature and PCM liquid fraction. Nevertheless, although the increase in fin length can lower the temperature difference, the influence of fin thickness and TEC input current on the temperature difference is tiny. Based on the numerical findings, the optimal fin length and thickness of 7 mm and 3 mm are obtained. In this situation, when the TEC input current is 3 A, the maximum temperature, temperature difference, and PCM liquid fraction in Case 1 are 315.10 K, 2.39 K, and 0.002, respectively, and those are respectively 318.24 K, 3.60 K, and 0.181 in Case 2. The configuration of Case 1 outperforms that of Case 2, due to the fewer TECs and greater distance from the battery pack to the TEC within Case 2. When experiencing a higher battery discharge rate, the TEC input current should also be correspondingly increased to ensure the temperature performance of the battery. The relative findings contribute to new insights into battery thermal management. • A novel BTMS combined with thermoelectric coolers and phase change materials is proposed. • A transient thermal-electric-fluid multi-physical field numerical model for the BTMS is developed. • The fin length, thickness, and TEC input current are suggested at 7 mm, 3 mm, and 3A. • The proposed BTMS can ensure battery temperature performance at high discharge rates. [ABSTRACT FROM AUTHOR]