Experimental study of forced-air cooling with heat spreaders for lithium-ion battery thermal management

Effective thermal management is crucial for the safety, performance, and lifespan of lithium-ion batteries, especially as electric vehicles become more prevalent in the worldwide shift toward sustainable transportation. Excessive temperature rises during charging and discharging of batteries can decrease efficiency, lead to uneven cell aging, and create safety hazards. This experimental study examined a hybrid cooling system that merges forced air convection with a copper mesh heat spreader. Compared to passive cooling, this proposed approach provides a notable improvement in thermal regulation. At a 0.5C charging rate, the hybrid system lowered the peak cell temperature by as much as 32 °C, and at 1C with an airflow of 3 m/s, it achieved a maximum temperature reduction of 71.71 %. Additionally, the method enhanced temperature uniformity across the battery module, reducing thermal gradients that can lead to cell degradation. Besides its thermal performance, the system offers a lightweight, compact, and affordable alternative to traditional liquid cooling methods. The fan-based system with a copper mesh heat spreader provides a practical option for applications where weight and maintenance are key considerations. This current research establishes the foundation for future studies into more advanced cooling solutions. Future investigations should focus on nano-enhanced liquid cooling and sophisticated phase change material systems to manage higher power densities and more demanding thermal loads in next-generation battery technologies.