BTMS CPMC Project Proposal
BTMS CPMC Project Proposal
Material (CPCM)
pg. 1
systems in vehicles helps to make decisions for improved design and shortens the
development process.
Need and opportunity:
For Growing Demand for Electric Vehicles (EVs): The global shift towards electric
vehicles (EVs) is accelerating, driven by the need to reduce greenhouse gas
emissions and dependence on fossil fuels. EVs rely heavily on lithium-ion batteries,
which are sensitive to temperature variations. Overheating or excessive cooling can
lead to reduced battery life, lower efficiency, and potential safety risks, including
thermal runaway. Developing an efficient and reliable Battery Thermal Management
System (BTMS) is crucial for ensuring the optimal performance and safety of EVs. For
Renewable Energy Storage: The integration of renewable energy sources like solar
and wind into the power grid is increasing, requiring efficient energy storage solutions.
Batteries are key to storing this energy, but they must be managed effectively to ensure
consistent performance. A PCM-based BTMS can help maintain battery efficiency in
energy storage systems, particularly in environments with fluctuating temperatures.
For Safety and Performance Concerns: Thermal management is critical for preventing
overheating, which can lead to catastrophic failures in batteries, such as fires or
explosions. Additionally, maintaining an optimal temperature range is essential for
maximizing battery efficiency and performance. A PCM-based BTMS provides a
passive cooling solution that can absorb excess heat during charging and discharging
cycles without requiring active energy input. For Advancements in Materials Science:
Conventional cooling methods may not be sufficient for next-generation high-capacity
batteries. The development and application of advanced PCMs tailored for specific
temperature ranges and battery chemistries present an opportunity to create highly
efficient, customized thermal management solutions. This can keep pace with the
rapid advancements in battery technologies, ensuring that thermal management does
not become a limiting factor. For Sustainability and Energy Efficiency: There is a
growing emphasis on sustainability and reducing the environmental impact of
industrial processes and products. Traditional cooling systems can be energy-
intensive and contribute to the overall carbon footprint of a product. PCM-based BTMS
can offer a more sustainable alternative by reducing the need for active cooling
mechanisms, which consume electricity. Additionally, many PCMs can be sourced
from non-toxic, recyclable materials, aligning with broader goals of environmental
sustainability. For Market Potential and Economic Viability: As the market for EVs and
renewable energy systems expands, there is a significant economic opportunity in
developing cost-effective and scalable thermal management solutions. Innovating in
this area could lead to the development of new products and services, creating
economic value and driving growth in the clean energy industry.
pg. 2
cooling strategies. Liquid cooling is more expensive and complex, but the heat
transfer, especially at higher temperatures, and the control of temperatures are better.
The research also outlined the development of correct thermal models and comsol
simulations, which would go a long way in predicting and optimizing the performance
of battery cooling.
On another plane, it explores hybrid MgO/GO-modified microencapsulated phase
change materials for thermal energy management. Phase change materials
microencapsulated with materials like graphene oxide and magnesium oxide, which
increase thermal conductivity, act to improve stability, and prevent leakage. These
developments make them quite suitable for various thermal management applications,
including battery thermal management systems and renewable energy technologies.
Future research involves the optimization of production processes, as well as the
extension of applications of these hybrid MEPCMs in the field of energy storage and
management.
Reviews from a few specific papers are as follows:
• Paper: https://www.sciencedirect.com/science/article/pii/S0959652623045572
Development of hybrid MgO/GO modified microencapsulated phase change
material for thermal energy management: An experimental approach V.
Aiswarya a , Sudev Das a,* , Prajwal D. Watmode a,b , Sameer S. Gajghate b
pg. 3
array, to analyze the combined effects of four critical parameters: channel width,
channel height, the number of pipes, and coolant flow velocity. The research
conclusion shows that the most influential parameters on the average
temperature and temperature uniformity of a cooling plate are the number of
pipes and coolant velocity. The orthogonal design method enables the
evaluation of multiple factors while minimizing the number of experiments
involved. It can efficiently find the optimum parameter combination with better
cooling performance and hence is a useful reference for BTMS design in
electric vehicles. The paper illustrates, in a very practical way, how orthogonal
experimental design can be applied to the optimization of complex thermal
management systems, showing its potential for application in other engineering
designs.
The part on material and methods is where all the detailed materials used, synthesis
processes, and characterization techniques employed in the study are brought out.
Materials: In the study, various materials were used: paraffin wax (99% purity),
melamine powder, formaldehyde solution, magnesium nitrate hexahydrate
(Mg(NO3)2·6H2O, 99.9% purity), pellets of sodium hydroxide (NaOH),
ethylenediamine, sodium lauryl sulfate (SLS), and expandable graphite with 350 mesh
size—these were all purchased from Sigma Aldrich. The experiments were conducted
in deionized water (DI).
Synthesis of MgO by Sol–Gel Process: MgO was prepared through the sol-gel route.
To this end, a solution was made by dissolving magnesium nitrate hexahydrate and
SLS in deionized water. After that, NaOH was added to the above solution to form a
viscous white gel. Afterwards, the gel was stirred overnight, filtered, neutralized, dried
at 80°C, and calcined at 500°C to get the final white MgO powder.
Synthesis of Graphene Oxide (GO) by Hummers Method: In the present study, GO
was synthesized by a modified Hummer method. Graphite flakes were mixed with
H2SO4 and NaNO3, stirring in an ice bath. Then, KMnO4 was added; the mixture was
kept at 98°C and cooled. Hydrogen peroxide was added to terminate the reaction,
which was then washed, neutralized, and dried to obtain pure GO.
Preparing Melamine-Formaldehyde (MF) Prepolymer Solution: A prepolymer solution
was prepared by mixing melamine powder, formaldehyde, and DI water. Stir at 70°C
until the mixture is transparent and colorless.
Development of MEPCMs through In-Situ Polymerization: The focus of the study is
the development of microencapsulated phase change materials modified with
MgO/GO using the in-situ polymerization process. A mixture of paraffin, SLS, NaOH,
and DI water was heated up to 70°C to form an emulsion. The pH was adjusted to be
acidic and MgO/GO dispersion was added. Then the MF prepolymer was added drop
pg. 4
by drop with stirring for 3 hours. The process was terminated with ethylenediamine to
obtain white microcapsules, which were further neutralized, vacuum-dried, and stored.
Components, along with the proportions in each sample, are summarized in a table
given in this paper.
Characterization
The synthesized MEPCMs were characterized for morphology, elemental
composition, crystallinity, chemical structure, and thermal properties by using various
characterization techniques such as SEM-EDX, XRD, FTIR, and TGA, respectively.
SEM-EDX: Used to analyze the morphology and elemental composition.
XRD: This was used for studying crystallinity with a diffractometer equipped with a Cu-
Kα source.
FTIR: Chemical structures and compositions are characterized within the range of
400-4000 cm⁻¹.
DSC: The method has been used in measuring thermal properties and performances
of phase change, with the encapsulation rate, Er, estimated through the enthalpy of
phase transition.
TGA: The test is used to study the thermal stability of the MEPCMs from room
temperature up to 500°C under an inert nitrogen atmosphere.
Using Bragg’s law. The cubic interplanar spacing ‘d’ is determined.
where n, λ, θ, and a denotes the order of reflection, wavelength (m), angle of incidence,
and lattice constant between the (h, k, l) lattice plane, respectively.
The chemical structures and compositions of the synthesized MgO/GO
nanocomposites, MF resin, and MEPCMs were characterized using an FTIR Vertex
80v spectrometer (Bruker, Germany). The KBr pellet method was employed for
processing powdered samples, and FTIR spectra were obtained across a
wavenumber range of 400 cm⁻¹ to 4000 cm⁻¹ at room temperature. Thermal properties
and phase change behavior of approximately 5-7 mg of both bulk paraffin and
MEPCMs, with and without thermal conductivity enhancers (TCE), were assessed
using a differential scanning calorimeter (DSC Q20 V24.11). Measurements were
conducted under a pure nitrogen atmosphere with a heating rate of 5°C/min over a
temperature range from ambient to 80°C. The enthalpy of phase transition derived
from DSC results was utilized to calculate the encapsulation rate (Er) of the
synthesized MEPCMs, defined as the ratio of the core material's mass to the total
mass of the microcapsule, as expressed by the following equation.
pg. 5
where Δ Hm represents the melting enthalpy of the sample.
Besides, a form-stability test was carried out at 80°C for 3 hours, and leakage tests
were carried out for different numbers of hours to testify the stability and performance
of the MEPCMs.
The surface morphology of the raw materials and the developed CPCMs was
examined using a scanning electron microscope (SEM, HITACHI TM3030). These
observations were conducted at various magnifications with different acceleration
voltages. The SEM was equipped with Energy Dispersive X-ray Spectrometry (EDX)
to facilitate elemental analysis. The specific surface area was determined as the
surface area of the material per unit of volume. Pore volume was calculated as the
difference between the volume of interest (VOI) and the volume occupied by the EG
matrix. Porosity was calculated using the following formula.
pg. 6
cycles to ensure repeatability. Specific heat measurements were performed using a
sapphire as a reference material.
“where 𝑚𝑠𝑎𝑝 and 𝐶𝑝𝑠𝑎𝑝 are known, which represent the weight and specific heat of the sapphire,
respectively. 𝑞̇𝑠𝑎𝑝 and 𝑞̇𝑏𝑙 denote the heat flow applied to the sapphire and blank samples,
respectively. 𝑞̇𝑚𝑒𝑎𝑠 is the measured total heat flow and 𝑚𝑠𝑎𝑚 is the measured sample weight.”
pg. 7
that of the round tube. The BTMS module was similar to Tesla's BTMS, which was
very safe and efficient during fast charging. The BTMS module housed a battery pack
with 20 cylindrical cells. Inside the battery pack, a metallic cooling channel in the form
of a ribbon, 2mm wide, snaked through it; it was set horizontally in a series
configuration with respect to the batteries. Horizontal and vertical spacings between
cells were 7.8 and 3.6mm, respectively. These gaps between the batteries and the
cooling pipe were filled with CPCM. Heat generated by these individual cells was
transferred first to the CPCM and then to the cooling liquid circulating in the cooling
pipe. The battery cells were numbered Cell 1 thru Cell 20. Simulations were initialized
with an initial temperature of 298K throughout the domain, water as the HTF, inlet
velocities of 0.1m/s, 0.01m/s and 0.001m/s. Pressure outlet was kept at the exit of the
cooling channel.
pg. 8
Mathematical modelling:
pg. 9
The phase-change process of the PCM is modeled using the enthalpy-porosity
method, with the melting and solidification behaviors simulated through the melting
and solidification model. Natural convection and thermal radiation within the CPCM
are disregarded due to the confinement of the PCM within the interstitial voids of the
EG/PCM composite. A non-equilibrium thermal model is applied to describe the heat
transfer in the metal foam-based CPCM, with separate energy equations solved for
both the porous media and the PCM. In the governing equations, 𝜌 denotes the
density; 𝑢, 𝑣, and 𝑤 represent the velocity components in the 𝑥, 𝑦, and 𝑧 directions,
respectively; subscripts 𝑓, 𝑐, and 𝑚𝑒 correspond to the heat transfer fluid (HTF),
composite, and metal foam, respectively; 𝑘 stands for thermal conductivity; 𝜀
represents the metal foam porosity; and ℎ𝑠𝑓 and 𝐴𝑠𝑓 indicate the local heat transfer
coefficient and the surface area, respectively.
pg. 10
where ℎ𝑟𝑒𝑓, 𝑇𝑟𝑒𝑓, and 𝐶𝑝 represent the reference enthalpy, reference temperature,
and the specific heat of the PCM at constant pressure, respectively, while 𝐿 is the
latent heat. The term 𝛽 denotes the liquid fraction; 𝑆𝑥, 𝑆𝑦, and 𝑆𝑧 are momentum sinks
defined by 𝑆𝑖 = 𝐶𝑢𝑖 (1 − 𝛽)²/(𝛽³ + 𝛾), where i represents the x, y, or z direction; C is a
constant reflecting the characteristics of the mushy zone, assigned a numerical value
of 10⁵ in this study. The constant 𝛾 is used to prevent division by zero. Before solving
the above equations, several parameters for the metal foam/paraffin composite were
evaluated, and these are summarized as follows: the effective thermal conductivities
of the metal foam and PCM, denoted by 𝑘𝑚𝑒 and 𝑘𝑝𝑐𝑚, respectively, were calculated
using a three-structured model.
pg. 11
To verify the accuracy and reliability of the numerical model for the metal foam/PCM
composite, a validation simulation using a 2D model was conducted. This simulation
compared the model's results with experimental data available in the literature. The
validation case was based on the work of Zhao et al., where a rectangular
configuration (0.2 × 0.025 m) containing metal foam embedded with paraffin wax as
the PCM was analyzed. The numerical code used for validation was consistent with
that employed in the current study. In the validation process, the initial temperature of
the entire computational domain was set at 20 °C, and a heat flux of 1.6 kW/m² was
applied. The results showed a reasonable agreement between the numerical model
and experimental data, confirming the model's validity. This provides confidence in the
numerical methods and models used in the present study. Additionally, the
investigation of the copper foam/paraffin composite, detailed in Chapter 4, further
validates the accuracy of the copper foam/paraffin model.
Performance analysis:
Experimental setup for evaluating thermal performance: The thermal storage and
release capabilities of the MEPCMs were assessed by exposing the samples to
multiple cycles of heating and cooling, with temperatures ranging from ambient to 80°C
(Aiswarya and Das, 2023). The experimental setup for performance analysis is
depicted in Fig. 3. The sample, placed in an aluminum container, was heated using a
constant temperature heating plate. Once the sample reached 80°C, the container
was removed from the heating plate and allowed to cool. During this thermal cycling
process, type K thermocouples embedded within the sample were connected to a Data
pg. 12
Acquisition (DAQ) system, which recorded the temperature-time data throughout the
experiment.
Uncertainty analysis: The primary sources of uncertainty in the performance analysis
arise from the type K thermocouples used, the DSC measurements for melting point
and phase change behavior, and the thermal conductivity measurements obtained via
the KD2 Pro device. The maximum variation in thermal conductivity measured by the
KD2 Pro is 0.005 W/mK. The DSC instrument provides melting point measurements
with a precision of 0.18°C and phase change temperature values with an accuracy of
±1.5%. The type K thermocouples were calibrated using a dry block temperature
calibrator with a range from ambient temperature to 650°C, ensuring high accuracy
and resolution during the experiments.
Results and Discussion:
Morphology of Microcapsules: The morphological properties and elemental
composition of the microcapsules were analyzed using Scanning Electron Microscopy
(SEM) and Energy-Dispersive X-ray Spectroscopy (EDX), respectively. The results, as
shown in Fig. 4, indicate that the MEPCMs (microencapsulated phase change
materials) exhibit a nearly spherical shape with no signs of aggregation, consistent
with the findings of Camtakan et al. (2012). During the phase transition, the shell area
remained constant while the volume of the paraffin core changed. The average
diameter of the microcapsules was determined to be approximately 5 μm.
The incorporation of MgO/GO (magnesium oxide/graphene oxide) into the
microcapsules maintained the structural integrity without causing any observable
damage, likely due to effective heat dissipation preventing faults or breakage in the
microcapsule shells. EDX analysis confirmed that the unmodified microcapsules
primarily consisted of carbon (C), nitrogen (N), oxygen (O), aluminum (Al), and sulfur
(S). In contrast, the MgO/GO-modified samples lacked aluminum and displayed a
uniform distribution of magnesium (Mg), indicating the successful integration of MgO.
The higher concentrations of carbon and oxygen in the modified MEPCMs correspond
to the presence of graphene and an increased oxygen content, respectively. It is
important to note that a thinner shell is more prone to deformation; however, SEM
images did not reveal any cracks or damages in MEPCMs with a higher content of co-
fillers. In samples containing 0.05% and 0.10% MgO/GO/MEPCM, the outer shell
showed signs of damage and holes, as illustrated in Fig. 5. These samples also
exhibited relatively lower thermal conductivity values.
Transmission Electron Microscopy (TEM) images of the MEPCMs, including the shell
damages, are presented in Fig. 6. The TEM results showed that the unmodified
MEPCMs have a paraffin core encased in a uniform melamine-formaldehyde (MF)
shell. The shell thickness of the MEPCMs is only a few tens of nanometers.
Chemical Composition Analysis: The Fourier Transform Infrared (FTIR) spectra of both
unmodified and modified MEPCMs are presented in Fig. 7. The spectra display peaks
at 2916 cm⁻¹ and 2846 cm⁻¹, which correspond to the stretched vibrations of the C–H
group in alkanes. Additionally, the in-plane vibrational peaks of the methyl group
pg. 13
(ACH₂) bending are observed at 1465 cm⁻¹ and 720 cm⁻¹. The peak at 720 cm⁻¹,
specifically associated with (CH₂)n (n ≥ 4), indicates the presence of paraffin.
A new peak at 1334 cm⁻¹ is attributed to the NO₃⁻ vibration, as reported by Lee et al.
(2001). This peak likely arises from the binding of NO₂ to the metal sites of MgO,
leading to the dissociation of NO₂ into NO₃⁻ and NO. The peaks at 815 cm⁻¹ and 1546
cm⁻¹ are linked to the out-of-plane and in-plane vibrations of the triazine ring,
respectively. The absorption peaks at 1546 cm⁻¹ and 1465 cm⁻¹ are due to multiple
C–N stretching vibrations within the triazine ring, indicating the presence of melamine-
formaldehyde (MF), as noted by Eid et al. (2023b).
The distinctive peaks of MF and paraffin in the FTIR spectra of the MEPCMs confirm
the successful encapsulation of paraffin within the MF resin. These results
demonstrate that the MF shell effectively encases the nano-enhanced composite
material, ensuring the integrity of the MEPCMs.
X-Ray Diffraction (XRD) Analysis: The XRD patterns of the modified MEPCMs and the
Joint Committee on Powder Diffraction Standards (JCPDS) reference pattern for MgO
are depicted in Fig. 8 (a) and (b), respectively. The results reveal a distinct graphene
peak (002) at approximately 29.0° (Geng et al., 2011). The MgO peaks observed at
2θ = 37°, 42.9°, and 78.8° correspond to the (111), (200), and (222) cubic structure
planes, respectively, as reported by Ikram et al. (2021). These peaks are consistent
with the JCPDS 75-1525 reference pattern for MgO.
Additionally, the diffraction pattern at 42.5° is attributed to the (200) plane, which is
characteristic of MgO/GO particles, as noted by Baghbaderani et al. (2022). A peak at
42.26° for the (10) plane in the XRD spectra indicates the presence of layered
graphene in short-range order, as identified by Stobinski et al. (2014).
The XRD results confirm the successful interaction of MgO and GO within the modified
MEPCM samples, demonstrating the effective incorporation of thermally conductive
elements (TCE) into the microcapsules.
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• https://www.sciencedirect.com/science/article/pii/S0959652623045572
Development of hybrid MgO/GO modified microencapsulated phase change
material for thermal energy management: An experimental approach V.
Aiswarya a , Sudev Das a,* , Prajwal D. Watmode a,b , Sameer S. Gajghate b
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pg. 15
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pg. 16