3D-Printed Hybrid Liquid-CPCM Cooling Modules for High-Performance Thermal Management of Lithium-Ion Pouch Cells

Efficient thermal management is critical for ensuring the safety, performance, and durability of lithium ion pouch cells (LIPCs), particularly under high power operating conditions where conventional battery thermal management systems (BTMS) struggle to balance cooling effectiveness, structural simplicity, and weight. Here, we report a lightweight hybrid BTMS that synergistically integrates active liquid cooling with composite phase change material (CPCM) based thermal buffering through a 3D printed hexagonal architecture. The system is fabricated via a two step additive manufacturing process that enables sealed CPCM encapsulation and isolated liquid cooling pathways within a single carbon fiber reinforced nylon module, effectively eliminating leakage risks while allowing precise geometric control. Hexagonally partitioned CPCM cavities maximize the CPCM wall interfacial area and shorten internal conduction paths, accelerating latent heat absorption, while embedded serpentine liquid channels provide continuous convective heat removal and prevent CPCM saturation. A nanocarbon enhanced CPCM is employed to overcome the intrinsic low thermal conductivity of conventional paraffin based materials.