Optimizing Cylindrical Battery Cooling: Numerical Investigation of a Next-Gen Thermal Architecture

¹ Laboratory of Computer and Mathematical Process Engineering, National School of Applied Sciences, Sultan Moulay Slimane University, Khouribga, Morocco
² Cadi Ayyad University, UCA, National School of Applied Sciences, LaRTID Laboratory, Marrakech, Morocco

^* Corresponding author: This email address is being protected from spambots. You need JavaScript enabled to view it.

Published online: 22 May 2026

Abstract

The growing demand for high-performance lithium-ion (Li-ion) batteries in electric vehicles and portable electronics necessitates efficient thermal management solutions. This study numerically investigates a novel battery thermal management system (BTMS) that integrates aluminum fins with secondary branches embedded in a phase change material (PCM). The influence of the number of secondary fins on the thermal response of the system during battery discharge is analyzed using the enthalpy–porosity method. Results show that the introduction of secondary fins significantly reduces the maximum battery surface temperature by enhancing heat conduction and promoting more uniform heat distribution within the PCM. However, the increased fin density leads to slower PCM melting, as the higher metallic volume reduces the amount of PCM and stores part of the heat through sensible conduction. Consequently, the overall fusion process is delayed, although temperature uniformity is improved. The configuration with two secondary fins per branch provides the best compromise between temperature reduction, melting efficiency, and material usage, making it a promising passive cooling approach for Li-ion battery systems.