Thermal management of lithium-ion batteries: Numerical evaluation of phase change materials and fin designs against air cooling

Abstract

Optimal thermal management is critical for ensuring the safety and longevity of lithium-ion batteries (LIBs), yet efficient thermal regulation remains challenging. This study investigates air cooling and phase change material (PCM)-based strategies, examining how fin geometry (disk versus sinusoidal) and quantity affect thermal performance. A three-dimensional numerical model was developed using the enthalpy-porosity method to simulate PCM melting, with validation against experimental data. Seven cooling configurations were evaluated, including air cooling, PCM-only cooling, and PCM combined with copper fins of varying geometries (disk and sinusoidal) and quantities (one to three). The module comprised a tightly packed array of 18650-type LIB cells, with uniform heat generation applied under 3C discharge/charge conditions. Two key novelties are presented: a comparative evaluation of cooling strategies and a quantified thermal–mass trade-off relevant to electric vehicles and aerospace applications. Results show that air cooling produced a 12 K temperature gradient, with final row temperatures reaching 318 K. PCM reduced peak temperature by ∼16 K and improved temperature uniformity. Increasing fin count from 1 to 3 enhanced uniformity by 35.2 %, with fin number more influential than shape. The two-fin configuration offered optimal balance, lowering temperature variation by 28 % with only a 3.26 % increase in system mass.

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