Additively Manufactured Battery Thermal Management Systems (B-TMS): Experimental Investigations and Finite-Element Modeling

A highly efficient Battery Thermal Management System (B-TMS) in an electric vehicle (EV) achieves a dual-purpose: it simultaneously reduces both the peak average temperature (Tmax) of the battery pack and minimizes temperature variations (ΔT) among individual cells within the pack. This study introduces a comprehensive exploration combining experimental investigations and computational modeling of B-TMS solutions that incorporate advanced two-dimensional materials such as graphene and boron nitride within polymer composites. Our research focuses on evaluating the performance of additively manufactured B-TMS systems, including poly (lactic acid) (PLA), graphene-PLA, graphite-PLA, and BN-PLA. Leveraging empirically derived thermal data, we employ finite element analysis of transient heat conduction to simulate heat distribution in various composite structures. We present the impact of 2D material concentration, material type, and microstructure on Tmax and ΔT, offering valuable insights into their roles within the system.