Hybrid Cooling and Phase Change Material Framework for HighPerformance EV Batteries

Abstract

The increasing adoption of electric vehicles (EVs) has intensified the demand for advanced battery thermal management systems capable of ensuring safety, reliability, and high energy efficiency under diverse operating conditions. Lithium-ion batteries generate substantial heat during fast charging, rapid discharging, and highpower operation, making effective thermal regulation essential for preventing thermal runaway and performance degradation. Hybrid cooling systems that combine active cooling techniques with Phase Change Materials (PCMs) have emerged as an effective solution for improving thermal performance while minimizing energy consumption. This paper presents a Hybrid Cooling and Phase Change Material (HC-PCM) framework integrating liquid cooling, PCM-based passive thermal storage, intelligent temperature monitoring, and predictive thermal analytics for highperformance EV battery systems. Experimental evaluation demonstrates significant reductions in peak battery temperature, improved thermal uniformity, enhanced charging efficiency, lower cooling energy consumption, extended battery lifespan, and improved operational safety. The proposed framework provides a scalable, energyefficient, and reliable thermal management solution for next-generation electric vehicle battery technologies.