To improve the operating performance of the large-capacity battery pack of electric vehicles during continuous charging and discharging and to avoid its thermal runaway, in this paper we propose a new hybrid thermal management system that couples the PCM with the liquid cooling plate with microchannels. The flow direction of the microchannel structure in the bottom plate is designed according to the characteristics of the large axial thermal conductivity of the battery, and the cooling performance of the whole system under continuous charge/discharge cycles is numerically simulated. The results show that the hybrid PCM/liquid cooling plate can maintain good cooling performance under the discharge process of a large-capacity battery pack. After each cycle the temperature of the battery pack can be reduced to less than 30°, and the maximum temperature change rate of multiple cycles is controlled within 0.8%. With the application of the hybrid PCM/liquid-cooled plate battery cooling system, a safe temperature range of the battery pack is ensured even under multiple cycles of charging and discharging. The present work can facilitate future optimizations of the thermal management system of the large-capacity battery pack of electric vehicles.

The lithium-ion battery is widely used in the power system of pure electric vehicles and hybrid electric vehicles due to its high energy density. However, the chemical and electrochemical reactions generate a lot of heat. If the heat is not transferred through some refrigeration methods in time, it will lead to a rapid rise in the temperature of the battery. In this paper, an electric–thermal coupling model of a cylindrical Panasonic 21700 battery was proposed by using offline parameter identification method. Based on this model, a battery thermal management system using a heat pipe was established. The experimental results show that the model can simulate the actual performance of battery well. When the ambient temperature is 25 °C, the battery parameters change little and battery performance is better. The heat pipe battery thermal management system performs better than the non-heat pipe battery system in the discharge process, and can control the battery temperature well at low and high temperatures. Changing the refrigerant temperature can achieve a better thermal management effect under suitable ambient temperature conditions.