Sustainable and Eco-Friendly Battery Thermal Management System Based on Hybrid Cooling for Electric Vehicles

Authors

  • Akshay P M Department of Mechanical Engineering, Adi Shankara Institute of Engineering and Technology, A P J Abdul Kalam Technological University Author
  • Drupad R Nair Department of Mechanical Engineering, Adi Shankara Institute of Engineering and Technology, A P J Abdul Kalam Technological University Author
  • Jyothish Kumar P K Department of Mechanical Engineering, Adi Shankara Institute of Engineering and Technology, A P J Abdul Kalam Technological University Author
  • Rahul S Arackal Department of Mechanical Engineering, Adi Shankara Institute of Engineering and Technology, A P J Abdul Kalam Technological University Author
  • P M Sutheesh National Institute of Technology Calicut image/svg+xml Author

DOI:

https://doi.org/10.21467/proceedings.7.5.13

Keywords:

Battery Thermal Management System, Hybrid Cooling, Simple Air Cooling

Abstract

Lithium-ion batteries are a crucial component of electric vehicles (EVs), directly impacting their performance, safety, and efficiency. To function optimally, these batteries require precise thermal regulation, maintaining an operating temperature between 15°C and 35°C during both charging and discharging cycles. Keeping the battery within this range extends its lifespan, reduces thermal stress, and minimizes the risk of overheating, which can lead to thermal runaway—a significant safety concern in EV applications. However, existing cooling methods, including air cooling, liquid cooling, phase change materials (PCM), and nanofluid integration, have limitations, especially when exposed to diverse operating conditions and environments. This study introduces an innovative hybrid cooling system that integrates liquid cooling and forced air cooling with evaporative cooling. By utilizing forced air to enhance evaporative cooling, this approach maintains a continuous cooling effect, while liquid cooling efficiently dissipates excess heat to ensure stable temperatures. Beyond improving thermal management, this system helps extend battery life, optimize energy efficiency, and lower the risk of overheating. Its compact design also makes it adaptable for various EV applications, such as passenger vehicles, commercial fleets, public transportation, and stationary energy storage solutions. With its ability to accommodate different thermal demands, this hybrid cooling system presents a highly adaptable and reliable solution for EV technology. By improving battery performance and longevity, it aligns with industry goals to create safer, more durable, and environmentally friendly electric vehicles, ultimately accelerating the transition to sustainable transportation.

References

[1] R. Youssef et al., “Effect analysis on performance enhancement of a novel and environmental evaporative cooling system for lithium-ion battery applications,” Journal of energy storage, vol. 37, no. 5, p. 102475, May 2021, doi: 10.1016/J.EST.2021.102475. Available: https://www.sciencedirect.com/science/article/pii/ S2352152X21002243

[2] G. A. P. Rao and S. S. Kumar, “A Review of Integrated Battery Thermal Management Systems for Lithium-Ion Batteries of Electric Vehicles,” e-Prime, vol. 8, p. 100526, Jun. 2024, doi: 10.1016/j.prime.2024.100526

[3] R. Youssef, T. Kalogiannis, H. Behi, A. Pirooz, J. Van Mierlo, and M. Berecibar, “A comprehensive review of novel cooling techniques and heat transfer coolant mediums investigated for battery thermal management systems in electric vehicles,” Energy Reports, Nov. 2023, doi: 10.1016/j.egyr.2023.07.041

[4] C. Zhao, B. Zhang, Y. Zheng, S. Huang, T. Yan, and X. Liu, “Hybrid Battery Thermal Management System in Electrical Vehicles: A Review,” Energies, vol. 13, no. 23, p. 6257, Nov. 2020, doi: 10.3390/EN13236257.

[5] S. Vikram, S. Vashisht, D. Rakshit, and M. P. Wan, “Recent advancements and performance implications of hybrid battery thermal management systems for Electric Vehicles,” Journal of energy storage, Jun. 2024, doi: 10.1016/j.est.2024.111814

[6] Sutheesh. P. M., A. A. P., and R. B., “Comparative study of fiber materials for enhanced performance of hybrid cooling in battery thermal management systems,” Appl. Energy, vol. 371, p. 123671, 2024, doi: 10.1016/j.apenergy.2024.123671

[7] S. Shahid and M. Agelin‐Chaab, “Comparison of Hybrid Cooling Concepts with PCM Cooling for Electric Battery Packs,” Journal of fluid flow, heat and mass transfer, Jan. 2023, doi: 10.11159/jffhmt.2023.010

[8] S. Shahid and M. Agelin‐Chaab, “Experimental and numerical analysis of a hybrid cooling concept for an electric battery module,” International Journal of Heat and Fluid Flow, vol. 106, p. 109320, Apr. 2024, doi: 10.1016/j.ijheatfluidflow.2024.109320

[9] I. Torrano, J. Martín-Ortiz, J. Dauvergne, Á. Serrano, and D. Bielsa, “Thermal optimization of cylindrical lithium-ion hybrid thermal management system based on shape-stabilized phase change materials under realistic operating conditions,” Journal of Power Sources, vol. 617, p. 235148, Oct. 2024, doi: 10.1016/j.jpowsour.2024.235148

[10] D. M. Weragoda, G. Tian, Q. Cai, K. H. Lo, and Y. Gao, “Conceptualization of a novel battery thermal management system based on capillary-driven evaporative cooling,” Thermal science and engineering progress, Dec. 2023, doi: 10.1016/j.tsep.2023.102320

[11] J. E. Martínez-Legaz, “Recent advancement and enhanced battery performance using phase change materials based hybrid battery thermal management for electric vehicles,” Renewable & Sustainable Energy Reviews, vol. 154, p. 111759, Feb. 2022, doi: 10.1016/j.rser.2021.111759

Downloads

Published

2025-09-23

Issue

Vol. 7 No. 5 (2025): Proceedings of the International Conference on Innovations in Mechanical Robotics Computing and Biomedical Engineering: ICIMRBE 2025

Section

Articles

License

Creative Commons License

This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License.

How to Cite

[1]
P. M. Akshay, D. R. Nair, J. K. P K, R. S. Arackal, and P. M. Sutheesh, “Sustainable and Eco-Friendly Battery Thermal Management System Based on Hybrid Cooling for Electric Vehicles”, AIJR Proc., vol. 7, no. 5, pp. 100–110, Sep. 2025, doi: 10.21467/proceedings.7.5.13.