International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 12 Issue: 09 | Sep 2025
p-ISSN: 2395-0072
www.irjet.net
THERMAL ANALYSIS ON BATTERY THERMAL MANAGEMENT FOR LITHIUM ION BATTERY USING ALUMINUM FOAM AND PARAFFIN PCM COMPOSITE Jilla Anshu Prasanna1, M. Shailaja2 1Student, Dept. of Mechanical Engineering, JNTUH, Telangana, India 2Professor, Dept. of Mechanical Engineering, JNTUH, Telangana, India
---------------------------------------------------------------------***--------------------------------------------------------------------Abstract - Lithium-ion batteries are increasingly adopted in electric vehicles and portable electronics because of their high
energy density, efficiency, and long cycle life, yet they are highly sensitive to temperature variations, and excessive heat generation during charge–discharge cycles can negatively influence performance, safety, and service life. Passive thermal management systems employing Phase Change Materials (PCMs), particularly paraffin wax, have attracted attention due to their high latent heat capacity, which enables effective absorption of excess thermal energy; however, their inherently low thermal conductivity restricts rapid heat dissipation during high-rate operations. To overcome this limitation, the present study investigates a hybrid Battery Thermal Management System (BTMS) in which paraffin wax is integrated with thermally conductive aluminium foam to enhance overall heat transfer within a prismatic lithium-ion battery module. A transient thermal simulation was performed using ANSYS 2024 R2 Student Edition to evaluate the hybrid system over a duration of 1800 seconds, focusing on key thermal parameters such as temperature distribution, total heat flux, and directional heat flux. Simulation outcomes revealed that the battery’s maximum temperature reached 80 °C while the average temperature stabilized around 27 °C, demonstrating effective passive cooling performance. Moreover, aluminium foam significantly enhanced thermal conductivity within the PCM matrix, as evidenced by a peak heat flux of 1172 W/m² at 1800 s and improved directional heat flow across the module. These findings highlight that PCM–aluminium foam composites represent a promising, cost-effective, and efficient passive solution for battery thermal management, ensuring improved safety, durability, and operational reliability without reliance on active cooling mechanisms.
Key Words: Lithium-ion battery, Battery Thermal Management System (BTMS), Phase Change Material (PCM), Paraffin wax, Aluminum foam, Passive cooling, Thermal conductivity, Temperature distribution . 1.INTRODUCTION The rapid adoption of electric vehicles (EVs), hybrid electric vehicles (HEVs), and renewable energy storage systems has placed a significant focus on lithium-ion batteries (LIBs) due to their high energy density, long cycle life, and favorable power-to-weight ratio [1–3]. However, the performance, safety, and longevity of LIBs are strongly influenced by their operating temperature. Heat generated during charge–discharge processes a rises from ohmic losses, electrochemical reactions, and entropy changes [4]. Without appropriate control, excessive heat leads to non-uniform temperature distribution, accelerated degradation, reduced efficiency, and in severe cases, thermal runaway [5]. Studies indicate that LIBs perform optimally within a narrow temperature range of 20–40 °C; deviations below this range increase internal resistance and lower ionic conductivity, while elevated temperatures accelerate side reactions such as solid electrolyte interphase (SEI) growth and electrolyte decomposition [6,7]. Furthermore, uneven temperature distribution among cells within a module can result in local hotspots, leading to imbalance and safety risks [8]. To mitigate these challenges, an efficient Battery Thermal Management System (BTMS) is indispensable. The primary functions of a BTMS include dissipating excess heat during high load or fast charging conditions, providing heating in low-temperature environments, and ensuring uniform temperature distribution across the battery pack [9]. Various BTMS technologies have been investigated in recent years. Air cooling systems, which rely on natural or forced convection, are simple, lightweight, and cost-effective, but limited by the low thermal conductivity of air, making them suitable primarily for low–medium power applications [10]. Liquid cooling systems, employing water, glycol, or dielectric fluids in cooling channels or plates, exhibit higher heat transfer coefficients and improved uniformity, and are widely implemented in modern EVs [11,12].
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