The Effect of Continuous Cycling on Battery Thermal Management System with Integrated PCM and Heat Sink

The global imperative to reduce carbon emissions has led to the widespread adoption of electric vehicles (EVs) as a potential solution. However, managing the significant heat generated by EV batteries remains a critical challenge. This study investigates the effectiveness of a passive cooling thermal management system for EV batteries that integrates phase change materials (PCM) and Heat sink. The research examines variations in heat generation power applied to a heater connected to a battery simulator, which mimics the operational heat losses during battery use, at power levels of 20 W, 30 W, 40 W, 50 W, 60 W, and 70 W, under varying ambient temperatures of 28 °C, 32 °C, and 40 °C. The PCM used in this study is a pure PCM (Rubitherm RT35 HC). Battery temperature measurements were conducted using an RTD PT 100 sensor interfaced with data acquisition system. The results indicate that under continuous cycling, the combination of PCM and heatsink significantly reduce battery temperature fluctuations and maintains it within a safe range (15 °C-35 °C). This integrated approach underscores the potential of passive cooling methods in battery thermal management systems for electric vehicles, primarily attributed to the PCM’s superior thermal conductivity and heat capacity, which play a crucial role in maintaining the battery within its recommended operating temperature range.