DESIGN AND ANALYSIS OF INTEGRATED AIR-LIQUID BTMS FOR EVS

Abstract

Electric vehicles (EVs) rely heavily on lithium-ion battery packs, the performance, safety, and lifespan of which are profoundly governed by operating temperatures. Conventional battery thermal management systems (BTMS) typically rely on either forced air or liquid cooling in isolation. While air-cooling systems are lightweight and cost-effective, they suffer from inadequate heat dissipation under high-load conditions; conversely, liquid-cooling systems offer exceptional thermal performance but introduce structural complexity and heavy parasitic power consumption. To address these trade-offs, this paper presents the Design and Analysis of Integrated Air-Liquid BTMS for EVs. The proposed hybrid architecture combines structural forced-air convection channels for baseline thermal regulation with mini-channel liquid cold plates for high-rate fast charging and peak load mitigation. Utilizing detailed Bernardi heat generation modeling and computational fluid dynamics (CFD) simulations, the study evaluates the thermal performance across various discharge rates and ambient environments. The results demonstrate that the integrated hybrid approach successfully restricts maximum cell temperatures below the critical 4????∘C threshold and limits internal temperature gradients to under ±????∘C, all while optimizing auxiliary parasitic power consumption to preserve vehicle driving range.