Design of novel thermal management system for Li-ion battery module using metal matrix based passive cooling method

Reliable, efficient and safe energy storage is important for electric vehicles and renewable energy storage of power grid. Lithium-ion battery is preferred as energy storage device due to its higher energy density, low self-discharge and longer cycle life. Lithium-ion cells generate heat during high discharge rates and harsh ambient temperature operation, which raises cell temperature and impacts its performance. Therefore, an efficient thermal management system (TMS) is necessary to alleviate thermal issues during charge/discharge process. A combination of phase change material (PCM) with high conductive plate metal matrix is proposed to eliminate the limitation on the heat transfer characteristics of air-cooled systems. To analyze the thermal and electrochemical behavior of a Lithium-ion cell, a detailed CFD simulation with empirical NTGK electro-chemical model is used. The model is first validated with available experimental data and the analysis is then extended to predict thermal response of individual cell of 3s3p module under natural convection boundary conditions. Poor heat transfer capability associated with natural convection at elevated temperature and discharge rate causes the cell maximum temperature (Tmax) and uniformity (ΔT) to be higher than acceptable values of 45 °Cand 3 °Crespectively. A thermal management system based on passive cooling using PCM is proposed and analyzed using CFD model by first validating the PCM melting behavior under uniform heating. The model is then extended to analyze the impact of PCM on cell temperature rise at different discharge rates of 8 A - 25 A (≈1C - 3.2C) and various operating temperatures of 25°C to 35°C. Low thermal conductivity of PCM limits heat dissipation which leads to higher temperature gradient. A novel TMS based on plate metal matrix structure enclosing PCM is proposed to enhance heat conduction across PCM and increase heat dissipation to maintain battery module under safe operating temperature limits. This approach has brought down the module maximum temperature to 44.1 °Cand temperature difference to 1.6 °Cduring operation at 25 A (3.2C) and 35 °C. Hence, PCM with high latent heat and low thermal conductivity could be used with high conductivity plate metal matrix to improve cell performance by keeping the cell temperature at required range.