Design and optimization of a hybrid cooling configuration combining PCM and liquid cooling for Li-ion battery using data-based response surface approximation model

Effective thermal management is crucial for safe operation of electric vehicles. This study proposes a novel hybrid cooling system that using phase change material (PCM) and liquid cooling to address issues such as leakage, non-uniform temperatures under high discharge rates. A comprehensive 3D model was developed to analyze the influence of geometric parameters on the cooling system. Response surface approximation modeling was used to optimize the layout parameters of the PCM. The results show that the hybrid cooling outperforms other methods, maintaining the cell temperature with 35 ℃ and the temperature difference within 4 ℃. The thickness of the PCM is a significant factor, as it increases heat storage capacity and reduces temperature; however, exceeding a certain threshold leads to increased thermal resistance. A non-uniform PCM layout can reduce the temperature difference by 26 %. An optimal PCM thickness of 2.5 mm to 3 mm ensures that the maximum temperature remains below 32.5 ℃, with a temperature difference within 2 ℃. The lowest temperature difference is achieved with a vertical layout height of 70 mm and a horizontal layout thickness of 3 mm. These findings are valuable for enhancing the thermal management of lithium-ion battery.