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In this study, a comprehensive simulation study was carried out to obtain detailed battery temperature behaviors. The influences of air inlet temperature, air flow rate, C‐rate, and free stream temperature were investigated on the temperature uniformity and maximal battery temperature. Taguchi design is implemented to investigate the main effects of four control parameters in the battery thermal management process. Results indicated that as the free stream temperature (delta = 7.3366) was the most influential factor for the temperature uniformity, the air inlet temperature (delta = 0.2679) was the most efficient factor for the maximal battery temperature. The contribution of the air inlet temperature was 28% and 38% for temperature uniformity and maximal battery temperature, respectively. Additionally, the free stream temperature contributed 32% to temperature uniformity and 25% to the maximum battery temperature. The airflow rate was found to be the least effective factor for temperature uniformity (delta = 2.8672) and maximal battery temperature (delta = 0.0506). The results could be helpful in the design of a lithium‐ion battery thermal management process to improve temperature uniformity and maximal battery temperature. [ABSTRACT FROM AUTHOR]

In order to improve cycle life and the working performance of the Li‐ion batteries and the reliability of battery thermal management (BTM) system, a composite matrix coupled with mini‐channel based BTM system is designed in this paper. The thermal performances of the BTM system at different discharge rates under the condition of air natural convection (ANC) and composite matrix (CM) are studied. The results show that the thermal conductivity of the PCMs/EG composites is about 28 times larger than the pure PCMs. Meanwhile, the latent heat is 134.28 J/g after adding EG. The batteries possess larger heat production both at larger state of charge (SOC) and lower SOC. Compared with ANC system, the highest temperature and the ΔTmax of the battery modules with CM system at the discharge rates of 3 C are 40.5°C and 2.4°C, respectively. When the battery modules coupled with mini‐channel, the 6 cooling channels with the inlet mass flow rate at 2 × 10−3 kg/s has the best cooling performance. The highest temperature of the packs could be controlled below 40.1°C and the ΔTmax is no more than 1.4°C during the cycle process at the discharge rate of 3 C(I = 30 Ah). [ABSTRACT FROM AUTHOR]