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In the present investigation, a novel hybrid battery thermal management system (HBTMS) has been introduced, that integrates copper metal foam both as longitudinal fins and as layers to simultaneously enhance passive and active cooling. A detailed numerical model was developed to simulate the thermal behaviour of a 12-cell 18650 NCM lithium-ion battery pack under cyclic 5C discharge and 3C charge conditions. The phase change material (PCM) was modelled using the enthalpy-porosity method, copper foam was simulated using Darcy–Brinkman–Forchheimer (DBF) model along with the local thermal equilibrium (LTE) model for fins and the local thermal non-equilibrium (LTNE) model for layers. Results indicate that the HBTMS maintains battery surface temperatures approximately 10 K below the safety threshold (323.15 K) across all cycles, ensures full PCM melting and re-solidification in each cycle, and limits the maximum temperature difference within the pack to below 2.5 K. In contrast to pure PCM cooling, which exhibited severe heat accumulation and thermal degradation, the proposed HBTMS demonstrated stable, reversible phase change behaviour and improved thermal reliability over extended cycling, making it a promising solution for high-performance battery systems.

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Numerical Investigation of Copper Foam-Integrated Hybrid Battery Thermal Management System for Enhanced Thermal Control and Cyclic Performance

  • 会议论文

  • 发表日期：

    2026年

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  • Alireza Keyhani-Asl,
  • Noel Perera,
  • Jens Lahr,
  • Reaz Hasan

摘要

In the present investigation, a novel hybrid battery thermal management system (HBTMS) has been introduced, that integrates copper metal foam both as longitudinal fins and as layers to simultaneously enhance passive and active cooling. A detailed numerical model was developed to simulate the thermal behaviour of a 12-cell 18650 NCM lithium-ion battery pack under cyclic 5C discharge and 3C charge conditions. The phase change material (PCM) was modelled using the enthalpy-porosity method, copper foam was simulated using Darcy–Brinkman–Forchheimer (DBF) model along with the local thermal equilibrium (LTE) model for fins and the local thermal non-equilibrium (LTNE) model for layers. Results indicate that the HBTMS maintains battery surface temperatures approximately 10 K below the safety threshold (323.15 K) across all cycles, ensures full PCM melting and re-solidification in each cycle, and limits the maximum temperature difference within the pack to below 2.5 K. In contrast to pure PCM cooling, which exhibited severe heat accumulation and thermal degradation, the proposed HBTMS demonstrated stable, reversible phase change behaviour and improved thermal reliability over extended cycling, making it a promising solution for high-performance battery systems.