Design and Optimization of a Thermal Management System for High-Performance Electric Vehicle Batteries Using Phase Change Materials

Abstract

Effective thermal management is critical for ensuring the safety, performance, and longevity of high-performance

electric vehicle (EV) batteries. This study presents the design, simulation, optimization, and experimental validation of

a phase change material (PCM)-based thermal management system (TMS) for lithium-ion battery modules. Various

PCM candidates, including composite materials enhanced with thermally conductive additives, are evaluated to

improve heat dissipation and mitigate localized hotspots. A three-dimensional thermal model of the battery pack is

developed using computational tools, incorporating heat generation, conduction, convection, and phase change

phenomena. Multi-objective optimization is applied to determine optimal PCM thickness, melting temperature, and

thermal conductivity to achieve uniform temperature distribution and minimize thermal stress. A small-scale prototype

of the optimized system is fabricated and tested under controlled charge-discharge cycles. Experimental results validate

the simulation findings, demonstrating that the PCM-based TMS effectively reduces peak temperatures, improves

thermal uniformity, and enhances overall battery performance. The proposed methodology provides a practical

approach for integrating advanced thermal management solutions in EV battery systems.