Numerical Investigation of Copper Foam-Integrated Hybrid Battery Thermal Management System for Enhanced Thermal Control and Cyclic Performance

Alireza Keyhani Asl; Noel Perera; Jens Lahr; Reaz Hasan

doi:10.1007/978-3-032-16138-3_37

Numerical Investigation of Copper Foam-Integrated Hybrid Battery Thermal Management System for Enhanced Thermal Control and Cyclic Performance

Alireza Keyhani Asl
, Noel Perera^*
, Jens Lahr
, Reaz Hasan

^*Corresponding author for this work

Department of Engineering

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

Abstract

In the present investigation, a novel hybrid battery thermal management system (HBTMS) has been introduced, that integrates copper metal foam both as longitudinal fins and as layers to simultaneously enhance passive and
active cooling. A detailed numerical model was developed to simulate the thermal behaviour of a 12-cell 18650 NCM lithium-ion battery pack under cyclic 5C discharge and 3C charge conditions. The phase change material (PCM) was
modelled using the enthalpy-porosity method, copper foam was simulated using
Darcy–Brinkman–Forchheimer (DBF) model along with the local thermal equilibrium (LTE) model for fins and the local thermal non-equilibrium (LTNE) model for layers. Results indicate that the HBTMS maintains battery surface temperatures approximately 10 K below the safety threshold (323.15 K) across all cycles, ensures full PCM melting and re-solidification in each cycle, and limits the maximum temperature difference within the pack to below 2.5 K. In contrast to pure PCM cooling, which exhibited severe heat accumulation and thermal degradation, the proposed HBTMS demonstrated stable, reversible phase change behaviour and
improved thermal reliability over extended cycling, making it a promising solution for high-performance battery systems.

Original language	English
Title of host publication	Advances in Computational Heat and Mass Transfer II
Publisher	Springer Nature
Pages	403-412
Number of pages	9
Volume	1
ISBN (Electronic)	9783032161383
ISBN (Print)	9783032161376
DOIs	https://doi.org/10.1007/978-3-032-16138-3_37
Publication status	Published (VoR) - 17 Feb 2026
Event	International Conference on Computational Heat and Mass Transfer - Antalya, Turkey Duration: 19 May 2025 → 22 May 2025 Conference number: 15

Conference

Conference	International Conference on Computational Heat and Mass Transfer
Abbreviated title	ICCHMT 2025
Country/Territory	Turkey
City	Antalya
Period	19/05/25 → 22/05/25

Keywords

Hybrid Battery Thermal Management System
Copper Foam
Lithium-ion batteries

Access to Document

10.1007/978-3-032-16138-3_37

Cite this

@inproceedings{8f7a63c0bb8346bf9322c2fb80e6da4e,

title = "Numerical Investigation of Copper Foam-Integrated Hybrid Battery Thermal Management System for Enhanced Thermal Control and Cyclic Performance",

abstract = "In the present investigation, a novel hybrid battery thermal management system (HBTMS) has been introduced, that integrates copper metal foam both as longitudinal fins and as layers to simultaneously enhance passive and active cooling. A detailed numerical model was developed to simulate the thermal behaviour of a 12-cell 18650 NCM lithium-ion battery pack under cyclic 5C discharge and 3C charge conditions. The phase change material (PCM) was modelled using the enthalpy-porosity method, copper foam was simulated using Darcy–Brinkman–Forchheimer (DBF) model along with the local thermal equilibrium (LTE) model for fins and the local thermal non-equilibrium (LTNE) model for layers. Results indicate that the HBTMS maintains battery surface temperatures approximately 10 K below the safety threshold (323.15 K) across all cycles, ensures full PCM melting and re-solidification in each cycle, and limits the maximum temperature difference within the pack to below 2.5 K. In contrast to pure PCM cooling, which exhibited severe heat accumulation and thermal degradation, the proposed HBTMS demonstrated stable, reversible phase change behaviour and improved thermal reliability over extended cycling, making it a promising solution for high-performance battery systems. ",

keywords = "Hybrid Battery Thermal Management System, Copper Foam, Lithium-ion batteries",

author = "\{Keyhani Asl\}, Alireza and Noel Perera and Jens Lahr and Reaz Hasan",

year = "2026",

month = feb,

day = "17",

doi = "10.1007/978-3-032-16138-3\_37",

language = "English",

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volume = "1",

pages = "403--412",

booktitle = "Advances in Computational Heat and Mass Transfer II",

publisher = "Springer Nature",

note = "International Conference on Computational Heat and Mass Transfer, ICCHMT 2025 ; Conference date: 19-05-2025 Through 22-05-2025",

}

Keyhani Asl, A, Perera, N , Lahr, J & Hasan, R 2026, Numerical Investigation of Copper Foam-Integrated Hybrid Battery Thermal Management System for Enhanced Thermal Control and Cyclic Performance. in Advances in Computational Heat and Mass Transfer II. vol. 1, Springer Nature, pp. 403-412, International Conference on Computational Heat and Mass Transfer, Antalya, Turkey, 19/05/25. https://doi.org/10.1007/978-3-032-16138-3_37

Numerical Investigation of Copper Foam-Integrated Hybrid Battery Thermal Management System for Enhanced Thermal Control and Cyclic Performance. / Keyhani Asl, Alireza; Perera, Noel ; Lahr, Jens et al.
Advances in Computational Heat and Mass Transfer II. Vol. 1 Springer Nature, 2026. p. 403-412.

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

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T1 - Numerical Investigation of Copper Foam-Integrated Hybrid Battery Thermal Management System for Enhanced Thermal Control and Cyclic Performance

AU - Keyhani Asl, Alireza

AU - Perera, Noel

AU - Lahr, Jens

AU - Hasan, Reaz

N1 - Conference code: 15

PY - 2026/2/17

Y1 - 2026/2/17

N2 - In the present investigation, a novel hybrid battery thermal management system (HBTMS) has been introduced, that integrates copper metal foam both as longitudinal fins and as layers to simultaneously enhance passive and active cooling. A detailed numerical model was developed to simulate the thermal behaviour of a 12-cell 18650 NCM lithium-ion battery pack under cyclic 5C discharge and 3C charge conditions. The phase change material (PCM) was modelled using the enthalpy-porosity method, copper foam was simulated using Darcy–Brinkman–Forchheimer (DBF) model along with the local thermal equilibrium (LTE) model for fins and the local thermal non-equilibrium (LTNE) model for layers. Results indicate that the HBTMS maintains battery surface temperatures approximately 10 K below the safety threshold (323.15 K) across all cycles, ensures full PCM melting and re-solidification in each cycle, and limits the maximum temperature difference within the pack to below 2.5 K. In contrast to pure PCM cooling, which exhibited severe heat accumulation and thermal degradation, the proposed HBTMS demonstrated stable, reversible phase change behaviour and improved thermal reliability over extended cycling, making it a promising solution for high-performance battery systems.

AB - In the present investigation, a novel hybrid battery thermal management system (HBTMS) has been introduced, that integrates copper metal foam both as longitudinal fins and as layers to simultaneously enhance passive and active cooling. A detailed numerical model was developed to simulate the thermal behaviour of a 12-cell 18650 NCM lithium-ion battery pack under cyclic 5C discharge and 3C charge conditions. The phase change material (PCM) was modelled using the enthalpy-porosity method, copper foam was simulated using Darcy–Brinkman–Forchheimer (DBF) model along with the local thermal equilibrium (LTE) model for fins and the local thermal non-equilibrium (LTNE) model for layers. Results indicate that the HBTMS maintains battery surface temperatures approximately 10 K below the safety threshold (323.15 K) across all cycles, ensures full PCM melting and re-solidification in each cycle, and limits the maximum temperature difference within the pack to below 2.5 K. In contrast to pure PCM cooling, which exhibited severe heat accumulation and thermal degradation, the proposed HBTMS demonstrated stable, reversible phase change behaviour and improved thermal reliability over extended cycling, making it a promising solution for high-performance battery systems.

KW - Hybrid Battery Thermal Management System

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KW - Lithium-ion batteries

U2 - 10.1007/978-3-032-16138-3_37

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M3 - Conference contribution

SN - 9783032161376

VL - 1

SP - 403

EP - 412

BT - Advances in Computational Heat and Mass Transfer II

PB - Springer Nature

T2 - International Conference on Computational Heat and Mass Transfer

Y2 - 19 May 2025 through 22 May 2025

ER -

Numerical Investigation of Copper Foam-Integrated Hybrid Battery Thermal Management System for Enhanced Thermal Control and Cyclic Performance

Abstract

Conference

Keywords

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