The increasing global demand for electric and hybrid vehicles calls for improved thermal management solutions for lithium-ion (Li-ion) batteries, essential to ensuring performance, safety, and lifespan. This study explores the design of composite enclosures with embedded copper thermal bridges as a passive thermal management solution for Li-ion battery modules. Through comprehensive three-dimensional computational fluid dynamics (CFD) simulations and experimental validation, the study examines the impact of cell configurations and inter-cell spacing on temperature distribution. Custom composite enclosures embedded with copper pins demonstrated enhanced heat dissipation, achieving up to a 16.62% reduction in surface temperature. These findings validate the potential of composite materials as a lightweight and efficient alternative to traditional metal casings, offering a safer and more effective thermal management solution aligned with the demands of electric vehicle applications.
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