Research Projects

The rapid advancement and demand to have rapid charging/discharging in electric vehicles (EVs) necessitates to develop advanced thermal management system capable of handling extreme fast charging demands. The conventional cooling methods are struggle to achieve high heat dissipation especially for 4C charging/discharging rate of the battery pack. This project aims to develop an advanced hybrid thermal management system combining phase change composites (PCC) and liquid metal cooling to address high heat dissipation which is a critical factor for efficient, safe, and high-power EV battery operation. Traditional passive cooling techniques alone are insufficient for the intense thermal loads generated during fast charging and discharging cycles. Therefore, this project explores a hybrid solution by integrating novel, nanomaterial-enhanced PCCs with gallium-based liquid metal cooling, hypothesizing that this approach will enable superior heat storage and dissipation, thereby maintaining battery temperatures within optimal operating ranges. The scientific objectives are multifaceted: (1) to design and fabricate high-stability PCCs capable of storing and rapidly releasing heat, (2) to characterize these composites using inverse heat conduction methods, assessing key thermophysical properties, and (3) to optimize PCC composition, including the effects of shape stabilizers, thermal conductivity enhancers (TCEs), and flame retardants. Additionally, the project will explore the use of liquid metal cooling channels to transfer heat absorbed by PCC to ambient conditions, crucial for continuous high-capacity operations. The methodology involves fabricating PCC with enhanced thermal conductivity using additives like expanded graphite, boron nitride, and incorporating flame retardants for improved safety. The hybrid cooling system will combine the high latent heat storage of PCC with active liquid metal cooling, aiming to prevent PCM saturation and enable efficient heat rejection during fast charging. Experimental setups will measure thermal performance, involving transient temperature analyses and IR thermography, complemented by computational simulations to predict system behavior under various charging/discharging rates (1C to 4C). The successful completion of the project will yield significant advancements in EV thermal management, including reduced charging times (targeting under 15 minutes), enhanced power capacity, extended range, and robust safety protocols against thermal runaway. The outcomes could influence industry standards for high-power charging, fostering compatibility across EV models and infrastructures. The proposed thermal management system will have ability to sustain extreme charging conditions without compromising battery lifespan supporting the evolving demands of the EV market.