Abstract: To mitigate safety risks associated with high discharge rates in 18650 lithium-ion battery packs—particularly excessive heat generation and insufficient thermal dissipation that may lead to temperatures surpassing safe operational limits—this study proposes two hybrid cooling systems. These systems integrate phase change materials (PCM) with either cylindrical or curvilinear quadrilateral heat pipes (PCM+HP). A numerical simulation approach was adopted to evaluate the comparative cooling performance of the two heat pipe geometries under three operational scenarios:(1) natural convection, (2) PCM+HP coupling, and (3) PCM+HP with fin-enhanced cooling. Key parameters such as fin thickness and spacing were systematically analyzed to optimize heat transfer enhancement. Simulation results demonstrated that at a 2C discharge rate, the maximum battery pack temperature with the curvilinear quadrilateral heat pipe configuration was 1.628 ℃ lower than that achieved with the cylindrical design. Under more demanding 3C conditions, the curvilinear quadrilateral system reduced the PCM’s average liquid-phase ratio by 24.9%, indicating superior latent heat utilization and thermal stability. Further optimization revealed that a fin thickness of 2 mm and spacing of 1 mm yielded the most significant improvements, markedly reducing both PCM liquid-phase ratios and peak battery temperatures, thereby enhancing overall pack safety.
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2026, Vol. 40 
