Enhanced Thermal Regulation of Lithium-Ion Batteries Using Composite PCM-Fin Structures for High Heat Dissipation

Poor thermal conductivity is common in batteries that use phase change material (PCM)-based thermal management systems (BTMS). This study introduces cylindrical rings and longitudinal fins to improve heat transfer. The thermal performance of several BTMS configurations is the primary focus of this analysis. The results show that the PCM–fin system offers superior temperature management compared to both pure PCM and pure battery systems. To understand the mechanisms, numerical simulations were compared against experimental data available in the literature. Numerical analysis shows that the fin shapes increase heat transmission and create a thermal conductive network inside the PCM, improving battery thermal performance. The study indicates that the effectiveness of thermal management is influenced by the number of extended surfaces and rings, as well as the heat generation rate. One cylindrical ring and eight longitudinal fins, with a dimensionless spacing of 0.2 between the battery and the ring, are recommended. The PCM–fin technology also effectively controls the battery's temperature rise at 20 W, proving its durability in high-heat conditions.