A Framework for Enhancing Thermal Management in Compact Electric Vehicle Batteries

Thesis Abstract

The increasing adoption of electric vehicles (EVs) necessitates the development of efficient thermal management systems (TMS) to ensure the safety, performance, and longevity of compact lithium-ion batteries. Thermal regulation remains a critical challenge due to the confined spaces and high heat generation during rapid charging and discharging cycles, which can lead to thermal runaway, capacity degradation, and reduced operational lifespan. This study aims to develop a comprehensive framework for enhancing thermal management in compact EV batteries, focusing on optimizing heat dissipation strategies to improve thermal stability and energy efficiency. The specific objectives are to identify the key thermal challenges in existing battery configurations, evaluate the efficacy of various cooling techniques through empirical testing, and formulate an integrated model combining passive and active cooling methods for scalable application. The research adopts a mixed-methods approach, integrating experimental investigations with computational modeling. A quantitative experimental design was employed, involving the testing of 50 battery cells sourced from a reputable EV manufacturer, representing different chemistries and configurations. These samples were subjected to standardized thermal cycling tests within a controlled laboratory environment. Data collection utilized infrared thermography for temperature mapping, thermocouples for internal temperature monitoring, and data acquisition systems for recording voltage, current, and thermal parameters during simulated charge-discharge cycles. Additionally, finite element analysis (FEA) models were developed to simulate heat transfer processes within the battery modules, calibrated using empirical data. The analytical framework includes regression analysis to identify the most significant variables affecting heat dissipation, along with thermodynamic assessments to compare the efficiency of passive versus active cooling strategies. Key anticipated findings include the identification of optimal cooling configurations tailored for the compact form factor, quantification of heat flux across different materials and designs, and the establishment of a scalable thermal management model that integrates passive heat spreaders with active liquid cooling. Results are expected to demonstrate that hybrid cooling approaches can significantly reduce peak temperatures by up to 20%, prevent thermal runaway incidents, and improve overall energy efficiency by minimizing unnecessary cooling energy expenditure. Furthermore, the study is likely to reveal critical material and design parameters that influence thermal performance, providing a basis for best practices in battery pack design. This research contributes novel insights into the development of a holistic thermal management framework that combines theoretical principles from heat transfer, battery thermodynamics, and systems engineering, underpinned by the Theory of Conduction and the Heat Transfer Enhancement Theory. It advances current knowledge by providing an empirically validated, scalable model capable of guiding future design improvements in compact EV batteries. The study’s findings are expected to influence industry standards and inform the development of next-generation battery thermal management systems, ensuring safer, more reliable, and energy-efficient EV operations. In conclusion, this research recommends adopting integrated hybrid cooling strategies that leverage passive heat spreaders and active liquid cooling, alongside materials optimization, to address thermal challenges in compact batteries. It emphasizes the need for standardized testing protocols and simulation-based design validation to accelerate the deployment of robust thermal management solutions across the EV industry. Future research directions include exploring the integration of phase change materials (PCMs) and phase change cooling techniques, along with the development of real-time thermal monitoring systems for adaptive control of cooling mechanisms. The study’s outcomes aim to bridge existing gaps in thermal management knowledge and promote sustainable practices in the design of compact electric vehicle battery systems.