The regulation of battery temperature within an optimal range and the mitigation of fluctuations during operation are essential technologies for enhancing the performance of electric vehicles. The incorporation of phase change material (PCM) within active battery thermal management systems (BTMS) is viewed as a promising direction for future advancements, yet an ideal structure for PCM implementation in BTMS to facilitate industrialization remains elusive. To leverage the thermal absorption and release properties of PCM for improving both high and low temperature stability, as well as mitigating temperature fluctuations in batteries, a novel BTMS integrating PCM energy storage tubes (PCM-EST) with liquid cooling has been proposed. This system employs two distinct groups of PCM-EST, where the low-temperature group (W-PCM-EST) acts as a heat source to elevate the battery temperature, and the high-temperature group (C-PCM-EST) functions as a cold source to dissipate excess heat within the coolant loop. Simulation models were developed and validated, with simulations conducted under WLTC test cycle. The simulation outcomes indicate the advantages and practicality of utilizing BTMS combined with PCM-EST for battery temperature management, showing a reduction in power consumption by 4.29%–5.54% under low temperature conditions and a decrease in compressor energy consumption by 8.3%–8.43% under high temperature scenarios. This research offers new insights and potential applications for PCM within BTMS.
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