Session: 17-01-01: Research Posters

Paper Number: 150392

150392 - Development and Optimization of Hybrid Heat Dissipation System for Lithium-Ion Battery Packs 

This study presents the development and optimization of an advanced hybrid heat dissipation system specifically designed for lithium-ion battery packs used in drone applications. The system employs a novel battery capsule filled with a phase change material (PCM) compound enhanced with 2% Huber nano-carbon, demonstrating superior thermal conductivity and stability. This innovative approach addresses the critical challenge of managing the high energy and compact design of drones, which demand efficient thermal management to ensure safety and performance.

The capsules were manufactured using advanced 3D printing technology, incorporating paraffin wax and carbon black powders as the PCM components. The integration of 2% Huber nano-carbon into the PCM significantly enhances its thermal conductivity, ensuring efficient heat transfer and dissipation. The thermal properties of the enhanced PCM were meticulously analyzed using Differential Scanning Calorimetry (DSC) and thermal conductivity measurements, confirming the improved heat dissipation capabilities. The oval-shaped capsules, with a major/minor axis ratio of 17.2/14.2 mm, were identified as the most effective design for maintaining the battery within a safe operating temperature range. This specific geometric optimization was determined through extensive thermal simulations and validated by experimental results.

Comparative studies were conducted to evaluate the performance of the PCM-filled capsules against air-filled and pure paraffin wax-filled capsules. The results demonstrated that the PCM-filled capsules significantly outperformed the other designs in terms of thermal management efficiency. The air-filled capsules showed inadequate heat dissipation, leading to higher battery temperatures, while the pure paraffin wax-filled capsules, although better than air-filled, did not match the efficiency of the nano-carbon-enhanced PCM. The PCM-filled capsules effectively maintained the battery temperature around 45°C, compared to higher temperatures observed in the other designs, under similar high-load conditions.

The system's dual approach, combining passive PCM cooling with active air cooling, proved to be highly effective in extending the battery's operational life and safety. The passive PCM cooling absorbs and stores heat, while the active air cooling dissipates the stored heat more efficiently. This synergy ensures optimal temperature regulation, preventing thermal runaway and enhancing battery longevity. Infrared thermal imaging and real-time temperature monitoring provided empirical evidence supporting the superior performance of the hybrid cooling system.

This research highlights the significant potential for integrating nano-carbon-enhanced PCMs in high-performance, temperature-sensitive devices. The findings suggest that this advanced thermal management system can be applied beyond drones, including electric vehicles, portable electronics, and advanced energy storage systems. The improved thermal conductivity and stability of the nano-carbon-enhanced PCM make it an ideal candidate for applications requiring efficient and reliable thermal management. Future work may explore the scalability of this system and its adaptability to other high-demand applications, paving the way for broader industrial adoption. The successful implementation of this hybrid cooling system represents a crucial advancement in the field of thermal management, offering a viable solution for the ever-increasing energy demands of modern technology.

Presenting Author: Xuguang Zhang Northeastern University

Presenting Author Biography: Xuguang Zhang is a dedicated PhD student at Northeastern University, specializing in the field of Nanoscale Thermal Transport. His research focuses on the intricate mechanisms of heat transfer at the nanoscale, aiming to enhance the thermal management systems of various advanced technologies.

Xuguang has made significant contributions to the field, including his latest publication in the prestigious journal Applied Thermal Engineering. His work involves the development and optimization of innovative hybrid heat dissipation systems for lithium-ion battery packs, with a particular emphasis on applications in drone technology.

Throughout his academic journey, Xuguang has demonstrated a strong commitment to advancing our understanding of thermal transport phenomena, contributing to the development of more efficient and reliable thermal management solutions. His expertise extends to the integration of phase change materials enhanced with nano-carbon, showcasing his ability to blend theoretical knowledge with practical applications.

Xuguang's research is driven by a passion for innovation and a dedication to solving real-world engineering challenges. He continues to push the boundaries of what is possible in nanoscale thermal transport, paving the way for new advancements in the field.

Authors:

Xuguang Zhang Northeastern University
Yang Liu Northeastern University
Michael Halbig NASA Glenn Research Center
Mrityunjay Singh Ohio Aerospace Institute
Amjad Almansour NASA Glenn Research Center
Yi Zheng Northeastern University