3D-Printed Hybrid Liquid-CPCM Cooling Modules for High-Performance Thermal Management of Lithium-Ion Pouch Cells

TL;DR

This paper introduces a lightweight, hybrid thermal management system for lithium-ion pouch cells that combines 3D-printed liquid cooling channels with composite phase change materials, enhancing safety and efficiency under high power conditions.

Contribution

The study presents a novel 3D-printed hybrid cooling module integrating active liquid cooling and CPCM with a sealed, leak-proof design for improved thermal regulation of lithium-ion batteries.

Findings

Enhanced heat absorption due to hexagonal CPCM cavities

Effective convective heat removal via embedded serpentine channels

Use of nanocarbon to improve CPCM thermal conductivity

Abstract

Efficient thermal management is critical for ensuring the safety, performance, and durability of lithium ion pouch cells (LIPCs), particularly under high power operating conditions where conventional battery thermal management systems (BTMS) struggle to balance cooling effectiveness, structural simplicity, and weight. Here, we report a lightweight hybrid BTMS that synergistically integrates active liquid cooling with composite phase change material (CPCM) based thermal buffering through a 3D printed hexagonal architecture. The system is fabricated via a two step additive manufacturing process that enables sealed CPCM encapsulation and isolated liquid cooling pathways within a single carbon fiber reinforced nylon module, effectively eliminating leakage risks while allowing precise geometric control. Hexagonally partitioned CPCM cavities maximize the CPCM wall interfacial area and shorten internal conduction paths, accelerating latent heat absorption, while embedded serpentine liquid channels provide continuous convective heat removal and prevent CPCM saturation. A nanocarbon enhanced CPCM is employed to overcome the intrinsic low thermal conductivity of conventional paraffin based materials.