This study presents an experimental investigation of a novel hybrid battery thermal management system (BTMS) that integrates a solenoid-actuated Peltier-based heat sink with a CuO/ethylene glycol (EG) nanofluid coolant loop. The system delivers on-demand cooling through time-controlled thermoelectric operation, enhancing temperature regulation during thermal surges. Experiments were conducted with CuO nanoparticle concentrations ranging from 0.5% to 2.0% (vol.) and coolant flow rates from 1 to 5 LPM, at an inlet coolant temperature of 50°C and ambient temperature of 26°C. Performance metrics such as temperature drop, heat transfer rate, and overall heat transfer coefficient were analyzed. Results showed a maximum heat transfer coefficient enhancement of 40.63% (tube-side) and 38.64% (air-side) at 2.0% CuO. Compared to a conventional liquid cooling system, the hybrid setup demonstrated a 7.01% higher heat transfer rate and improved temperature variation control (up to 28.53%). Life Cycle Cost (LCC) analysis demonstrates a 25%–30% reduction in long-term costs and ∼36% battery life extension, supporting the system’s economic viability. This scalable, energy-efficient BTMS offers a promising solution for advanced hybrid and electric vehicles requiring high-precision thermal control.
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