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<p>The operational robustness of battery thermal management systems (BTMS) under diverse and extreme conditions is critical for electric vehicle (EV) safety and longevity. This study presents a comprehensive numerical investigation into the performance limits and optimization potential of an advanced hybrid cold plate composed of a lightweight graphite fiber-reinforced aluminum (GFRA) composite with an integrated phase change material (PCM) layer. Using a validated 3D computational fluid dynamics model, the system’s performance was evaluated across a wide range of operational parameters. The BTMS demonstrated robust thermal control for discharge rates up to 6C, maintaining the maximum battery temperature (T<sub>max</sub>) below the critical 40 °C threshold. An analysis of varying ambient temperatures (10 °C to 45 °C) revealed the necessity of tailoring the PCM’s melting point to the operational climate, as a 50 °C melt PCM outperformed a 40 °C melt PCM by over 10 °C in extreme heat. Geometric optimization showed that increasing the number of microchannels from 3 to 7 could simultaneously reduce T<sub>max</sub> by 8 % and pressure drop by over 75 %. Furthermore, using an Al<sub>2</sub>O<sub>3</sub>-water nanofluid offered a modest thermal enhancement (up to 7.1 % T<sub>max</sub> rise reduction) at the cost of a significant hydraulic penalty (20.1 % pressure drop increase), indicating an optimal concentration exists around 0.3–0.5 % vol. This work provides a detailed performance map and optimization guidelines for tailoring advanced hybrid BTMS to real-world EV operating demands.</p>

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Performance and optimization of a hybrid composite-PCM battery cold plate under high C-rates, extreme temperatures and nanofluid cooling

  • 期刊论文

  • 发表日期：

    2026年3月10日

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  • Anirban Bose,
  • Arunabha Chanda

摘要

The operational robustness of battery thermal management systems (BTMS) under diverse and extreme conditions is critical for electric vehicle (EV) safety and longevity. This study presents a comprehensive numerical investigation into the performance limits and optimization potential of an advanced hybrid cold plate composed of a lightweight graphite fiber-reinforced aluminum (GFRA) composite with an integrated phase change material (PCM) layer. Using a validated 3D computational fluid dynamics model, the system’s performance was evaluated across a wide range of operational parameters. The BTMS demonstrated robust thermal control for discharge rates up to 6C, maintaining the maximum battery temperature (Tmax) below the critical 40 °C threshold. An analysis of varying ambient temperatures (10 °C to 45 °C) revealed the necessity of tailoring the PCM’s melting point to the operational climate, as a 50 °C melt PCM outperformed a 40 °C melt PCM by over 10 °C in extreme heat. Geometric optimization showed that increasing the number of microchannels from 3 to 7 could simultaneously reduce Tmax by 8 % and pressure drop by over 75 %. Furthermore, using an Al2O3-water nanofluid offered a modest thermal enhancement (up to 7.1 % Tmax rise reduction) at the cost of a significant hydraulic penalty (20.1 % pressure drop increase), indicating an optimal concentration exists around 0.3–0.5 % vol. This work provides a detailed performance map and optimization guidelines for tailoring advanced hybrid BTMS to real-world EV operating demands.