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Batteries
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Thermal Management in Lithium-Ion Batteries: Latest Advances and Prospects
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Thermal Management in Lithium-Ion Batteries: Latest Advances and Prospects

A special issue of Batteries (ISSN 2313-0105). This special issue belongs to the section "Battery Performance, Ageing, Reliability and Safety".

Deadline for manuscript submissions: 15 May 2025 | Viewed by 31807

Special Issue Editors

Dr. Xianglin Li

E-Mail Website
Guest Editor
Department of Mechanical Engineering and Materials Science, Washington University in St. Louis, St. Louis, MO 63130, USA
Interests: fuel cells; Li-O2 batteries; battery thermal management; heat and mass transfer in porous media
Dr. Chuanbo Yang

E-Mail Website
Guest Editor
National Renewable Energy Laboratory, Golden, CO 80401, USA
Interests: Li-ion battery; multiphysics modeling; battery safety and thermal management; fluid dynamics and control
Dr. Prahit Dubey

E-Mail Website
Guest Editor
Skyline Mobility Inc., Torrance, CA 90501, USA
Interests: battery thermal management system; BMS algorithms; modeling and simulation (CFD/FEA); aerodynamics

Special Issue Information

Dear Colleagues,

The rapidly expanding battery market presents an urgent requirement for reliable, efficient, and affordable thermal management and protection solutions. These solutions are crucial to improve the cycle life and performance, as well as to mitigate the risk of thermal runaway and catastrophic failures in battery packs. Addressing these pressing needs is of the utmost importance for the power electronics, electric vehicle, and battery industries. By enhancing the safety of battery packs, we can facilitate the widespread adoption of batteries in energy-intensive applications such as electric vehicles and grid-scale energy storage systems. In addition, a higher battery cycle life improves the long-term cost–benefit of a battery electric vehicle or energy storage system. Advanced thermal management strategies can also improve performance, such as fast charging and aggressive discharges across a large temperature band, which further supports battery technology adaptation. Therefore, there is a critical imperative to develop robust, efficient, and cost-effective thermal management strategies that ensure the performance, integrity, and stability of battery systems.

In light of the rapid growth witnessed in the electric vehicle and rechargeable battery markets, this Special Issue, entitled “Thermal Management in Lithium-Ion Batteries: Latest Advances and Prospects”, presents an opportune platform to explore diverse thermal management technologies. It specifically focuses on their application in battery and electronics systems for transportation applications, including passenger cars, trucks, buses, locomotives, boats, aircraft, and beyond, encompassing both established industry practices and emerging solutions for future advancements. By examining conventional approaches alongside cutting-edge innovations, this timely collection of articles aims to address the evolving demands of the field and foster insights into effective thermal management strategies.

We encourage contributions from diverse global stakeholders to foster a comprehensive and inclusive dialogue. Valuable insights and expertise from academic institutions, industry organizations, and national laboratories are highly valued and encouraged. Both experimental studies and numerical simulations are welcomed. Topics of interest for publication include, but are not limited to:

  • Assessment of industry approaches and emerging advancements;
  • Single-phase cooling (passive, direct active, indirect active, and hybrid);
  • Multi-phase cooling (phase change materials, evaporative cooling, immersion/submerged cooling);
  • Innovative cooling materials and structures;
  • Advanced sensors, thermal control, and fault detection;
  • Battery materials and designs with improved thermal properties;
  • Strategies to mitigate thermal runaway and propagation;
  • Cutting-edge models to gain insights into thermal-related degradation mechanisms;
  • New mechanistic models to understand degradation caused by thermal issues;
  • Fusion of machine learning algorithms to enhance the precision and efficiency of detection and prediction;
  • Extreme conditions such as extremely fast charge and low temperatures.

Dr. Xianglin Li
Dr. Chuanbo Yang
Dr. Prahit Dubey
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Batteries is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2700 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

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Published Papers (7 papers)

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Research

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24 pages, 8010 KiB  
Article
Enhancing Battery Pack Cooling Efficiency Through Graphite-Integrated Hybrid-Battery Thermal Management Systems
by Amin Rahmani, Mahdieh Dibaj and Mohammad Akrami
Batteries 2025, 11(3), 113; https://doi.org/10.3390/batteries11030113 - 17 Mar 2025
Viewed by 223
Abstract
This study investigates a hybrid-battery thermal management system (BTMS) integrating air-cooling, a cold plate, and porous materials to optimize heat dissipation in a 20-cell battery pack during charging and discharging cycles of up to 5C. A computational fluid dynamics (CFD) model based on [...] Read more.
This study investigates a hybrid-battery thermal management system (BTMS) integrating air-cooling, a cold plate, and porous materials to optimize heat dissipation in a 20-cell battery pack during charging and discharging cycles of up to 5C. A computational fluid dynamics (CFD) model based on the equivalent circuit model (ECM) is developed to simulate battery pack behavior under various cooling configurations, including different porous media and vortex generators placed between cells. The impact of battery pack configurations on heat generation is analyzed, and five different porous materials are tested for their cooling performance. The results reveal that, among the examined materials, graphite is the most effective in maintaining the battery temperature within an acceptable range, particularly during high C-rate charging. Graphite integration significantly reduces the thermal stabilization time from over an hour to approximately 600 s. Additionally, our parametric experiment evaluates the influence of ambient temperature, airflow velocity, and cold-plate temperature on the system’s cooling efficiency. The findings demonstrate that maintaining the cold-plate temperature between 300 K and 305 K minimizes the temperature gradient, ensuring uniform thermal distribution. This research highlights the potential of hybrid BTMS designs incorporating porous media and cold plates to enhance battery performance, safety, and lifespan under various operational conditions. Full article
(This article belongs to the Special Issue Thermal Management in Lithium-Ion Batteries: Latest Advances and Prospects)
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29 pages, 11229 KiB  
Article
Air-Outlet and Step-Number Effects on a Step-like Plenum Battery’s Thermal Management System
by Olanrewaju M. Oyewola, Emmanuel T. Idowu, Morakinyo J. Labiran, Michael C. Hatfield and Mebougna L. Drabo
Batteries 2025, 11(3), 87; https://doi.org/10.3390/batteries11030087 - 21 Feb 2025
Viewed by 452
Abstract
Optimizing the control of the battery temperature (Tb), while minimizing the pressure drop (∆P) in air-cooled thermal management systems (TMSs), is an indispensable target for researchers. The Z-type battery thermal management system’s (BTMS’s) structure is one of [...] Read more.
Optimizing the control of the battery temperature (Tb), while minimizing the pressure drop (∆P) in air-cooled thermal management systems (TMSs), is an indispensable target for researchers. The Z-type battery thermal management system’s (BTMS’s) structure is one of the widely investigated air-cooled TMSs. Several designs of air-cooled BTMSs are often associated with the drawback of a rise in ∆P, consequently resulting in an increase in pumping costs. In this study, the investigation of a Step-like plenum design was extended by exploring one and two outlets to determine possible decreases in the maximum battery temperature (Tmax), maximum battery temperature difference (∆Tmax), and pressure drop (∆P). The computational fluid dynamics (CFD) method was employed to predict the performances of different designs. The designs combine Step-like plenum and two outlets, with the outlets located at different points on the BTMS. The results from the study revealed that using a one-outlet design, combined with a Step-like plenum design, reduced Tmax by 3.52 K when compared with that of the original Z-type system. For another design with two outlets and the same Step-like plenum design, a reduction in Tmax by 3.45 K was achieved. For ∆Tmax, the use of a two-outlet design and a Step-like plenum design achieved a reduction of 6.34 K. Considering the ∆P performance, the best- and poorest-performing designs with two outlets reduced ∆P by 5.91 Pa and 3.66 Pa, respectively, when compared with that of the original Z-type design. The performances of the designs in this study clearly show the potential of two-outlet designs in reducing ∆P in systems. This study, therefore, concludes that the operational cost of the Step-like plenum Z-type BTMS can be reduced through the careful positioning of the two-outlet section, which will promote the design and development of current and future electric vehicle (EV) technologies. Full article
(This article belongs to the Special Issue Thermal Management in Lithium-Ion Batteries: Latest Advances and Prospects)
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25 pages, 6081 KiB  
Article
Hybrid Heat Pipe-PCM-Assisted Thermal Management for Lithium-Ion Batteries
by Nourouddin Sharifi, Hamidreza Shabgard, Christian Millard and Ugochukwu Etufugh
Batteries 2025, 11(2), 64; https://doi.org/10.3390/batteries11020064 - 7 Feb 2025
Viewed by 968
Abstract
A hybrid cooling method for 18650 lithium-ion batteries has been investigated using both experimental and numerical approaches for electric vehicle applications. The experimental setup includes a heater section, a phase change material (PCM) reservoir, and a cooling section. The heater section simulates battery [...] Read more.
A hybrid cooling method for 18650 lithium-ion batteries has been investigated using both experimental and numerical approaches for electric vehicle applications. The experimental setup includes a heater section, a phase change material (PCM) reservoir, and a cooling section. The heater section simulates battery heat generation with two cylindrical aluminum housings, each sized to match an 18650 battery, two cartridge heaters, and an aluminum heat sink. An airflow channel is incorporated into the cooling section. Heat transfers sequentially from the heaters to aluminum housings, the heat sink, through three copper-water heat pipes (HPs), to/from the PCM, and finally to the cooled air in the airflow channel. This innovative design eliminates direct contact between the PCM and the batteries, unlike recent studies where the PCM has been in direct contact with the batteries. Decoupling the PCM reduces system design complexity while maintaining effective thermal management. Temperature measurements at various locations are analyzed under different heater powers, air velocities, and scenarios with and without PCM. Results show that the experimental design effectively maintains battery temperatures within acceptable limits. For a power input of 16 W, steady-state temperatures are reduced by approximately 14%, 10%, and 4% with PCM compared to without PCM for air velocities of 2 m/s, 3 m/s, and 4 m/s, respectively. A transient three-dimensional numerical model was developed in ANSYS-FLUENT to provide insights into the underlying physics. The phase change was simulated using the enthalpy-porosity approach, with computational results showing reasonable agreement with experimental data. Full article
(This article belongs to the Special Issue Thermal Management in Lithium-Ion Batteries: Latest Advances and Prospects)
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16 pages, 18315 KiB  
Article
Effects of Non-Uniform Temperature Distribution on the Degradation of Liquid-Cooled Parallel-Connected Lithium-Ion Cells
by Takuto Iriyama, Muriel Carter, Gabriel M. Cavalheiro, Pragati Poudel, George J. Nelson and Guangsheng Zhang
Batteries 2024, 10(8), 274; https://doi.org/10.3390/batteries10080274 - 30 Jul 2024
Viewed by 1814
Abstract
Our previous work on an air-cooled stack of five pouch-format lithium-ion (Li-ion) cells showed that non-uniform temperature can cause accelerated degradation, especially of the middle cell. In this work, a stack of five similar cells was cycled at a higher C-rate and water-cooled [...] Read more.
Our previous work on an air-cooled stack of five pouch-format lithium-ion (Li-ion) cells showed that non-uniform temperature can cause accelerated degradation, especially of the middle cell. In this work, a stack of five similar cells was cycled at a higher C-rate and water-cooled to create a larger temperature gradient for comparison with the air-cooled stack. It was hypothesized that the larger temperature gradient in the water-cooled stack would exacerbate the degradation of the middle cell. However, the results showed that the middle cell degraded slightly slower than the side cells in the water-cooled stack. This trend is opposite to that in the air-cooled stack. This difference could be attributed to the combined effects of a smaller temperature rise and larger temperature gradient in the water-cooled stack than in the air-cooled stack. Post-mortem analysis of cycled cells and a fresh cell showed that the degradation mainly came from the anode. Increased lithium plating and decreased porosity in the side cells are possible mechanisms for the faster degradation compared with the middle cell. It was also found that all the cells in the water-cooled stack experienced a phenomenon of capacity drop and recovery after a low C-rate reference performance test and extended rest. This phenomenon can be attributed to lithium diffusion between the anode active area and the anode overhang area. Full article
(This article belongs to the Special Issue Thermal Management in Lithium-Ion Batteries: Latest Advances and Prospects)
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12 pages, 2116 KiB  
Article
Li-Ion Battery Thermal Characterization for Thermal Management Design
by Aron Saxon, Chuanbo Yang, Shriram Santhanagopalan, Matthew Keyser and Andrew Colclasure
Batteries 2024, 10(4), 136; https://doi.org/10.3390/batteries10040136 - 18 Apr 2024
Cited by 7 | Viewed by 3813
Abstract
Battery design efforts often prioritize enhancing the energy density of the active materials and their utilization. However, optimizing thermal management systems at both the cell and pack levels is also key to achieving mission-relevant battery design. Battery thermal management systems, responsible for managing [...] Read more.
Battery design efforts often prioritize enhancing the energy density of the active materials and their utilization. However, optimizing thermal management systems at both the cell and pack levels is also key to achieving mission-relevant battery design. Battery thermal management systems, responsible for managing the thermal profile of battery cells, are crucial for balancing the trade-offs between battery performance and lifetime. Designing such systems requires accounting for the multitude of heat sources within battery cells and packs. This paper provides a summary of heat generation characterizations observed in several commercial Li-ion battery cells using isothermal battery calorimetry. The primary focus is on assessing the impact of temperatures, C-rates, and formation cycles. Moreover, a module-level characterization demonstrated the significant additional heat generated by module interconnects. Characterizing heat signatures at each level helps inform manufacturing at the design, production, and characterization phases that might otherwise go unaccounted for at the full pack level. Further testing of a 5 kWh battery pack revealed that a considerable temperature non-uniformity may arise due to inefficient cooling arrangements. To mitigate this type of challenge, a combined thermal characterization and multi-domain modeling approach is proposed, offering a solution without the need for constructing a costly module prototype. Full article
(This article belongs to the Special Issue Thermal Management in Lithium-Ion Batteries: Latest Advances and Prospects)
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Review

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20 pages, 950 KiB  
Review
Recent Advances in Thermal Management Strategies for Lithium-Ion Batteries: A Comprehensive Review
by Yadyra Ortiz, Paul Arévalo, Diego Peña and Francisco Jurado
Batteries 2024, 10(3), 83; https://doi.org/10.3390/batteries10030083 - 1 Mar 2024
Cited by 12 | Viewed by 11241
Abstract
Effective thermal management is essential for ensuring the safety, performance, and longevity of lithium-ion batteries across diverse applications, from electric vehicles to energy storage systems. This paper presents a thorough review of thermal management strategies, emphasizing recent advancements and future prospects. The analysis [...] Read more.
Effective thermal management is essential for ensuring the safety, performance, and longevity of lithium-ion batteries across diverse applications, from electric vehicles to energy storage systems. This paper presents a thorough review of thermal management strategies, emphasizing recent advancements and future prospects. The analysis begins with an evaluation of industry-standard practices and their limitations, followed by a detailed examination of single-phase and multi-phase cooling approaches. Successful implementations and challenges are discussed through relevant examples. The exploration extends to innovative materials and structures that augment thermal efficiency, along with advanced sensors and thermal control systems for real-time monitoring. The paper addresses strategies for mitigating the risks of overheating and propagation. Furthermore, it highlights the significance of advanced models and numerical simulations in comprehending long-term thermal degradation. The integration of machine learning algorithms is explored to enhance precision in detecting and predicting thermal issues. The review concludes with an analysis of challenges and solutions in thermal management under extreme conditions, including ultra-fast charging and low temperatures. In summary, this comprehensive review offers insights into current and future strategies for lithium-ion battery thermal management, with a dedicated focus on improving the safety, performance, and durability of these vital energy sources. Full article
(This article belongs to the Special Issue Thermal Management in Lithium-Ion Batteries: Latest Advances and Prospects)
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45 pages, 13074 KiB  
Review
Review of Thermal Management Strategies for Cylindrical Lithium-Ion Battery Packs
by Mohammad Ahmadian-Elmi and Peng Zhao
Batteries 2024, 10(2), 50; https://doi.org/10.3390/batteries10020050 - 28 Jan 2024
Cited by 18 | Viewed by 11365
Abstract
This paper presents a comprehensive review of the thermal management strategies employed in cylindrical lithium-ion battery packs, with a focus on enhancing performance, safety, and lifespan. Effective thermal management is critical to retain battery cycle life and mitigate safety issues such as thermal [...] Read more.
This paper presents a comprehensive review of the thermal management strategies employed in cylindrical lithium-ion battery packs, with a focus on enhancing performance, safety, and lifespan. Effective thermal management is critical to retain battery cycle life and mitigate safety issues such as thermal runaway. This review covers four major thermal management techniques: air cooling, liquid cooling, phase-change materials (PCM), and hybrid methods. Air-cooling strategies are analyzed for their simplicity and cost-effectiveness, while liquid-cooling systems are explored for their superior heat dissipation capabilities. Phase-change materials, with their latent heat absorption and release properties, are evaluated as potential passive cooling solutions. Additionally, hybrid methods, such as combining two or more strategies, are discussed for their synergistic effects in achieving optimal thermal management. Each strategy is assessed in terms of its thermal performance, energy efficiency, cost implications, and applicability to cylindrical lithium-ion battery packs. The paper provides valuable insights into the strengths and limitations of each technique, offering a comprehensive guide for researchers, engineers, and policymakers in the field of energy storage. The findings contribute to the ongoing efforts to develop efficient and sustainable thermal management solutions for cylindrical lithium-ion battery packs in various applications. Full article
(This article belongs to the Special Issue Thermal Management in Lithium-Ion Batteries: Latest Advances and Prospects)
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