Development and optimization of hybrid heat dissipation system for lithium-ion battery packs

This study presents the development and optimization of an advanced hybrid heat dissipation system for lithium-ion battery packs designed explicitly for drone applications. The system employs a novel battery capsule filled with a phase change material (PCM) compound enhanced with 2 % Huber nano-carbon, demonstrating superior thermal conductivity and stability. The capsules were manufactured using 3D printing technology, with paraffin wax and carbon black powders as the PCM components. Thermal simulations and experimental results indicated that the oval-shaped capsules with a major/minor axis ratio of 17.2/14.2 mm provided the most effective heat dissipation, maintaining the battery within a safe operating temperature range. Comparative studies revealed that the PCM-filled capsules outperformed the efficiency of air-filled and pure paraffin wax-filled capsules in thermal management. The system's dual approach, combining passive PCM cooling with active air cooling, significantly extended the battery's operational life and safety by ensuring optimal temperature regulation. This research highlights the potential for integrating nano-carbon-enhanced PCMs in high-performance, temperature-sensitive devices, paving the way for broader applications in electric vehicles, portable electronics, and advanced energy storage systems.