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The global shift towards renewable energy and electric mobility has increased the adoption of electric and hybrid vehicles, which rely on lithium-ion batteries. For optimal performance, these batteries must operate within 15–35 °C, with a maximum temperature difference (∆Tb,max) below 5 °C between cells. This requires an effective Battery Thermal Management System (BTMS). In this study, we developed a hybrid BTMS for a three-cell battery module (3C discharge rate), combining an aluminum cold plate, nano-phase change material (nano-PCM), and copper foam. Thermal performance was analyzed using Computational Fluid Dynamics (CFD) to simulate heat transfer and fluid flow. After validating the numerical model with experimental data, we used CFD to simulate the performances of the proposed BTMS. Results show that, at an inlet velocity of 0.1 m/s, the Tb,max slightly exceeded 35 °C, requiring further optimization. Incorporating 10% MWCNT nano-PCM reduced Tb,max to 35.23 °C and ΔTb,max to 2.49 °C. Increasing the inlet velocity to 0.3 m/s further lowered Tb,max to 35.03 °C and ΔTb,max to 2.37 °C. Beyond this point, Tb,max, ΔTb,max, the Nusselt number, and the friction coefficient stabilized. Besides, it has been found that integration of 95% porous copper foam successfully maintained ΔTb,max below 5 °C while keeping Tb,max within the optimal range of 15 °C to 35 °C throughout the discharge cycle. These results highlight the effectiveness of the novel BTMS, demonstrating its potential to improve battery performance for electric mobility applications.

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CFD-Based Optimization of a Novel Hybrid Battery Thermal Management System for Electric Vehicles: Approaches and Applications for Smart Mobility

  • 章节

  • 发表日期：

    2026年

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  • Nassreddine Hmidi,
  • Hicham Kaddouri,
  • Ahmed Alami Merrouni,
  • Abdel-illah Amrani,
  • Elmiloud Chaabelasri

摘要

The global shift towards renewable energy and electric mobility has increased the adoption of electric and hybrid vehicles, which rely on lithium-ion batteries. For optimal performance, these batteries must operate within 15–35 °C, with a maximum temperature difference (∆Tb,max) below 5 °C between cells. This requires an effective Battery Thermal Management System (BTMS). In this study, we developed a hybrid BTMS for a three-cell battery module (3C discharge rate), combining an aluminum cold plate, nano-phase change material (nano-PCM), and copper foam. Thermal performance was analyzed using Computational Fluid Dynamics (CFD) to simulate heat transfer and fluid flow. After validating the numerical model with experimental data, we used CFD to simulate the performances of the proposed BTMS. Results show that, at an inlet velocity of 0.1 m/s, the Tb,max slightly exceeded 35 °C, requiring further optimization. Incorporating 10% MWCNT nano-PCM reduced Tb,max to 35.23 °C and ΔTb,max to 2.49 °C. Increasing the inlet velocity to 0.3 m/s further lowered Tb,max to 35.03 °C and ΔTb,max to 2.37 °C. Beyond this point, Tb,max, ΔTb,max, the Nusselt number, and the friction coefficient stabilized. Besides, it has been found that integration of 95% porous copper foam successfully maintained ΔTb,max below 5 °C while keeping Tb,max within the optimal range of 15 °C to 35 °C throughout the discharge cycle. These results highlight the effectiveness of the novel BTMS, demonstrating its potential to improve battery performance for electric mobility applications.