PHASE CHANGE MATERIAL-BASED THERMAL OPTIMIZATION OF ELECTRIC VEHICLE BATTERY PACKS

Abstract

Electric vehicle (EV) battery performance, safety, and lifespan are highly influenced by operating temperature. Excessive heat generation during high-rate charging, rapid discharging, and varying environmental conditions can accelerate battery degradation and increase the risk of thermal runaway. Phase Change Materials (PCMs) have emerged as an effective passive thermal management solution due to their high latent heat storage capacity and ability to maintain battery temperatures within the optimal operating range. This paper presents a PCMbased thermal optimization framework for lithium-ion battery packs by integrating intelligent thermal design, heat transfer enhancement, and predictive monitoring techniques. The proposed methodology combines optimized PCM placement, thermal conductivity enhancement materials, sensor-based temperature monitoring, and data-driven performance analysis to improve heat dissipation and temperature uniformity. Experimental evaluation demonstrates significant reductions in peak battery temperature, improved temperature distribution, enhanced charging efficiency, prolonged battery lifespan, and increased operational safety. The proposed thermal management framework provides a practical, energy-efficient, and scalable solution for nextgeneration electric vehicle battery systems. Keywords— Electric Vehicles, Battery Thermal Management System, Phase Change Material, Lithium-Ion Battery, Thermal Optimization, Heat Transfer, Energy Storage, Thermal Safety.