Simulation Analysis on Thermal Management of Electric Vehicle Batteries Using PCM and Forced Air Cooling

Abstract

Efficient thermal management is vital for maintaining the performance, safety, and lifespan of electric vehicle (EV) batteries. This study analyzes a hybrid cooling strategy combining Phase Change Material (PCM) and forced air cooling to address the limitations of conventional battery cooling systems. PCM provides passive thermal regulation by absorbing excess heat through latent heat storage, while forced air cooling enhances continuous heat dissipation and prevents PCM saturation. The integrated system is evaluated for temperature reduction, thermal uniformity, and its ability to manage high thermal loads during fast charging and high-discharge operations. Results indicate that the hybrid PCM–air cooling approach reduces peak battery temperatures by up to 8–15°C compared to air cooling alone and significantly improves temperature uniformity across battery cells. The findings suggest that PCM–forced air hybrid cooling is a promising, energy-efficient solution for next-generation EV battery packs, offering improved safety, reliability, and thermal stability.