Benha University

Mohamed Khaled Ahmed Hamed Saudi

Demonstrator

Faculty of Engineering, Shoubra Mechanical Engineering

Enhancing thermal management of lithium-ion batteries using phase change materials and expanded graphite: An experimental study

Journal of Energy Storage • 2025
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Publication Information
Authors Mohamed Kh. Saudi, Mohamed Emam, Hamdy Hassan, Hidetoshi Sekiguchi ,Ahmed S.G. Khalil
Keywords Electric vehiclesLithium-ion batteriesPhase change material, Expanded graphite,Thermal management
Journal Journal of Energy Storage
Publisher ELSEVIER
Volume Volume 130, 15 September 2025, 117427
Issue 15 September 2025, 117427
Pages 10
publication.type International
Paper Link Open Link
Supplementary Materials Not Available
Abstract
Electric and hybrid electric vehicles are promising alternatives to tackle environmental impact and greenhouse gas emissions associated with internal combustion engine vehicles. Electric vehicles have fueled the need for an efficient energy storage system to provide high power output, maximum energy density, and rapid charging. Lithium-ion batteries are a viable alternative as their high power density and energy capacity make them stand out from their long lifespan and quick charging capabilities. However, thermal energy generated during charging and discharging can cause safety concerns. In this regard, an experimental study was conducted to assess cooling performance using four distinct phase-change-materials (PCM): PARA-Block, RT-54 HC, RT-44 HC and RT-35 HC were tested in a cyclic test, which showed a reduction in the battery's maximum temperature to 59.6 °C, 57.6 °C, 50.9 °C, 51.9 °C respectively, compared to 76.4 °C with natural convection cooling. For further modification to achieve the cell's optimum operating temperature and shape stabilized material, various weight percentages of expanded graphite (EG) (3 %, 6 %, 12 %, 15 %) were added to obtain composite stable phase change material (CPCM). The results showed that the battery's highest temperature decreased by almost 55 % by adding 12 % EG to PCM RT 35 HC compared to natural cooling. In addition, the best conditions were applied for a four-battery pack.
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