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This study examines the thermal behavior of a cooling system that incorporates phase change materials (PCMs), focusing on the effects of varying liquid flow rates, PCM layer thicknesses, and cross-sectional areas. Experimental trials were carried out to evaluate how these parameters influence the peak temperature, rate of heat dissipation, and thermal resistance. Findings revealed that a higher liquid flow rate led to improved cooling performance; for example, the peak temperature dropped from 60 °C to 40.5 °C as the flow rate increased from 0.1 m/s to 0.5 m/s. Thermal resistance was notably affected by PCM dimensions: thinner layers (5 mm) and smaller cross-sectional areas (5 mm2) were associated with higher resistance values, reaching up to 3.08 °C/W, due to reduced heat storage capacity. In contrast, configurations with greater PCM volumes and optimized fluid flow demonstrated lower resistance and enhanced thermal transfer. These results underscore the effectiveness of PCM-based systems for thermal regulation, emphasizing the need to balance design parameters for optimal performance.

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Design and Optimization of Phase Change Material Systems for Efficient Thermal Regulation in EV Battery Cooling Systems

  • 会议论文

  • 发表日期：

    2026年

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  • Saravana Kumar Mahalingam,
  • Prakash Sekar,
  • Prabhahar Muthuswamy,
  • Saravanan Mari,
  • Srinivasan Madhavan,
  • Sriram Govindharaj

摘要

This study examines the thermal behavior of a cooling system that incorporates phase change materials (PCMs), focusing on the effects of varying liquid flow rates, PCM layer thicknesses, and cross-sectional areas. Experimental trials were carried out to evaluate how these parameters influence the peak temperature, rate of heat dissipation, and thermal resistance. Findings revealed that a higher liquid flow rate led to improved cooling performance; for example, the peak temperature dropped from 60 °C to 40.5 °C as the flow rate increased from 0.1 m/s to 0.5 m/s. Thermal resistance was notably affected by PCM dimensions: thinner layers (5 mm) and smaller cross-sectional areas (5 mm2) were associated with higher resistance values, reaching up to 3.08 °C/W, due to reduced heat storage capacity. In contrast, configurations with greater PCM volumes and optimized fluid flow demonstrated lower resistance and enhanced thermal transfer. These results underscore the effectiveness of PCM-based systems for thermal regulation, emphasizing the need to balance design parameters for optimal performance.