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<p>Thermal management is a critical factor for the safe and reliable operation of lithium-ion batteries, particularly under high C-rate charge–discharge conditions where substantial heat is generated. While phase change materials (PCMs) have been widely studied for passive cooling, the regeneration (freezing) of the PCM between cycles and the comparative role of different fin geometries in cylindrical battery modules remain insufficiently explored. This study develops a three-dimensional transient model in COMSOL Multiphysics, using the finite element method and a porous enthalpy formulation, to simulate the solidification of RT-58 paraffin in an annular sleeve surrounding a cylindrical cell. Two cooling strategies are examined: single-sided cooling, where only the inner wall is maintained at 293&#xa0;K, and dual-sided cooling, where both inner and outer walls are held at 293&#xa0;K. The model is verified via grid and time-step independence and validated against benchmark data for PCM freezing in cylindrical enclosures. The novelty of this work lies in (i) a unified comparison of radial and longitudinal fins at equal fin volume under both cooling modes and (ii) direct coupling of the optimized PCM–fin designs to a high C-rate battery model to assess peak temperature, temperature uniformity, and regeneration performance. For the finless PCM sleeve, switching from single- to dual-sided cooling reduces the complete freezing time from 1433.3 to 300.42&#xa0;s (79% reduction). Under single-sided cooling, three radial fins shorten the freezing time to 688.97&#xa0;s (52% reduction), while six longitudinal fins reduce it to 558.21&#xa0;s (61% reduction). In dual-sided cooling, the same fin configurations further decrease the freezing time to 248.33 and 218.57&#xa0;s, respectively. Coupling the PCM–fin sleeve to a cylindrical cell at 2C discharge shows that a 7.5-mm PCM layer without fins lowers the peak temperature from about 58 to 41&#xa0;°C, whereas adding fins reduces it to approximately 38&#xa0;°C (radial) and 39&#xa0;°C (longitudinal) and cuts the time above 40&#xa0;°C to around 20–22%. These results demonstrate that fin-structured PCMs offer a compact, passive, and effective strategy for next-generation thermal management of high-power lithium-ion batteries.</p>

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Enhanced thermal management of lithium-ion batteries using fin-structured phase change materials

  • 期刊论文

  • 发表日期：

    2026年7月10日

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  • Lifang Qiu,
  • Hamed Davoodi Jooneghani,
  • Ali Sarhadi,
  • Mojtaba Zarezadeh

摘要

Thermal management is a critical factor for the safe and reliable operation of lithium-ion batteries, particularly under high C-rate charge–discharge conditions where substantial heat is generated. While phase change materials (PCMs) have been widely studied for passive cooling, the regeneration (freezing) of the PCM between cycles and the comparative role of different fin geometries in cylindrical battery modules remain insufficiently explored. This study develops a three-dimensional transient model in COMSOL Multiphysics, using the finite element method and a porous enthalpy formulation, to simulate the solidification of RT-58 paraffin in an annular sleeve surrounding a cylindrical cell. Two cooling strategies are examined: single-sided cooling, where only the inner wall is maintained at 293 K, and dual-sided cooling, where both inner and outer walls are held at 293 K. The model is verified via grid and time-step independence and validated against benchmark data for PCM freezing in cylindrical enclosures. The novelty of this work lies in (i) a unified comparison of radial and longitudinal fins at equal fin volume under both cooling modes and (ii) direct coupling of the optimized PCM–fin designs to a high C-rate battery model to assess peak temperature, temperature uniformity, and regeneration performance. For the finless PCM sleeve, switching from single- to dual-sided cooling reduces the complete freezing time from 1433.3 to 300.42 s (79% reduction). Under single-sided cooling, three radial fins shorten the freezing time to 688.97 s (52% reduction), while six longitudinal fins reduce it to 558.21 s (61% reduction). In dual-sided cooling, the same fin configurations further decrease the freezing time to 248.33 and 218.57 s, respectively. Coupling the PCM–fin sleeve to a cylindrical cell at 2C discharge shows that a 7.5-mm PCM layer without fins lowers the peak temperature from about 58 to 41 °C, whereas adding fins reduces it to approximately 38 °C (radial) and 39 °C (longitudinal) and cuts the time above 40 °C to around 20–22%. These results demonstrate that fin-structured PCMs offer a compact, passive, and effective strategy for next-generation thermal management of high-power lithium-ion batteries.