Numerical evaluation of a thermal management system consisting PCM and porous metal foam for Li-ion batteries

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Numerical evaluation of a thermal management system consisting PCM and porous metal foam for Li‑ion batteries Y. Salami Ranjbaran1 · S. Jenabi Haghparast1 · M. H. Shojaeefard1 · G. R. Molaeimanesh1  Received: 2 July 2019 / Accepted: 30 October 2019 © Akadémiai Kiadó, Budapest, Hungary 2019

Abstract Batteries, especially lithium-ion ones, are the main energy sources of electric vehicles. In order to remove the generated heat in these batteries, passive cooling systems such as those employing phase change materials (PCMs) can be used, without any energy consumption. The main drawback of conventional PCMs is their low thermal conductivity, which can be solved by adding conductive additives to pure PCM. In this study, nine passive battery thermal management systems (BTMSs) based on paraffin wax as pure PCM, and copper foam as conductive additive, but with nine different amounts (from 1 to 9 vol%), are numerically simulated to reveal the role of additive content. The results show that the addition of metal foam greatly influences the time evolution of PCM liquid fraction. It is turned out that the addition of 6 vol% copper foam can create the best cooling effect and preserves the cell in the desired temperature range. In fact, adding more than this value can significantly reduce the heat absorption capacity of BTMS and makes the BTMS unreliable. Keywords  Conjugate heat transfer · Porous media · Battery thermal management system (BTMS) · Li-ion battery · Phase change materials (PCMs) List of symbols C Mushy zone parameter C2 Inertial resistance factor in Eq. (3) CP Heat capacity H Enthalpy per unit of mass K Permeability k Thermal conductivity L Latent heat for phase change material ṁ pq Rate of mass transfer from phase p to phase q ṁ qp Rate of mass transfer from phase q to phase p P Pressure S Source/sink term T Temperature ui Component of velocity vector along the ith axis V⃗ Velocity vector Greek symbols 𝛼 Volume fraction Γ Liquid fraction * G. R. Molaeimanesh [email protected] 1



Research Laboratory of Automotive Fluids and Structures Analysis, School of Automotive Engineering, Iran University of Science and Technology, Narmak Ave., Tehran 16846‑13114, Iran

Μ Dynamic viscosity 𝜌 Density 𝜑 Porosity Subscripts B Buoyancy eff Effective l Liquidus ref Reference value s Solidus

Introduction Today, according to the reduction in fossil fuel resources and also dangerous contaminants coming out of conventional vehicles, human is forced to design and utilize different types of electric vehicles (EVs) [1–3]. Lithium-ion (Li-ion) batteries are the main sources of energy in the mentioned vehicles due to their high power and energy density, long lifecycle and low rate of self-discharge [4–7]. However, the Li-ion batteries suffer from high level of heat generation while they work at high discharge rates. The excess amount of generated heat should be removed from the battery cells, otherwise it may cause thermal runaways and safety concerns [8–12]. In order to remove excess generated heat,

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