Design and Analysis of a Hybrid Heat Exchanger for Electric Vehicle Batteries Using Phase Change Material (PCM) and Nanofluid Cooling

Abstract

Lithium-ion batteries are widely used in electric vehicles, portable electronics, and renewable energy storage systems due to their high energy density and long cycle life. However, during charging and discharging processes, significant heat is generated inside the battery because of internal resistance and electrochemical reactions. If this heat is not properly dissipated, battery temperature can rise beyond the safe operating range, leading to reduced efficiency, accelerated degradation, and potential safety risks. To address this issue, an effective battery thermal management system (BTMS) is required. In this study, a hybrid cooling approach combining phase change material (PCM) and a heat exchanger is proposed to control battery temperature. The PCM absorbs heat generated by the battery through latent heat storage, while the heat exchanger removes accumulated heat using circulating fluid. Computational Fluid Dynamics (CFD) analysis was conducted to evaluate temperature distribution, heat flux, and cooling performance of the proposed system. Simulation results indicate that the hybrid cooling system significantly reduces the maximum battery temperature and improves thermal stability. The proposed approach demonstrates potential for improving battery efficiency, safety, and operational life.