High thermal performance lithium-ion battery pack including hybrid active–passive thermal management system for using in hybrid/electric vehicles

In this study, a novel Li-ion battery pack design including hybrid active–passive thermal management system is presented. The battery pack is suitable for using in hybrid/electric vehicles. Active part of the hybrid thermal management system uses distributed thin ducts, air flow and natural convection as cooling media while the passive part utilizes phase change material/expanded graphite composite (PCM/EG) as cooling/heating component to optimize the thermal performance of the proposed battery pack. High melting enthalpy of PCM/EG composite together with melting of PCM/EG composite at the temperature of 58.9 °C remains the temperature distribution of the battery units in the desired temperature range (below 60 °C). The temperature and voltage distributions in the proposed battery pack design consisting of battery units, distributed thin ducts and PCM/EG composite are calculated by numerical solving of the related partial differential equations. Simulation results obtained by writing M-files code in Matlab environment and plotting the numerical data are presented to validate the theoretical results. A comparison between the thermal and physical characteristics of the proposed battery pack and other latest works is presented that explicitly proves the battery pack performance.