A Pocket Design Chart for PCM Thickness in Small Prismatic Modules Under Stop-and-Go Duty

We develop a concise, practice-ready pocket design chart for selecting phase-change material (PCM) thickness in small prismatic lithium-ion modules under stop-and-go duty. A transient, enthalpy-based electro-thermal model is exercised in a compact design-of-experiments (DOE) that sweeps PCM thickness (۰, ۱.۵, ۳.۰, ۴.۵ mm) and ambient (۱۵, ۲۵, ۳۵ °C). Pass/fail guards enforce (i) a cell-level temperature ceiling, (ii) a packaging-uniformity target, and (iii) a melt-fraction utilization window to avoid both under-use and latent-heat exhaustion. From these runs, we extract the minimal passing thickness at each ambient and fit a simple pocket rule parameterized by a normalized duty-severity factor, enabling interpolation without exhaustive simulation. Results indicate a thin layer is generally sufficient at nominal ambient (~۱.۵ mm at ۲۵ °C), whereas hot ambient typically requires a medium layer (~۳.۰ mm at ۳۵ °C) to maintain limits with margin. Sensitivities are small and actionable: +۱۰% duty severity increases required thickness by ~۰.۳-۰.۶ mm; ~+۲۰% convection can save -۰.۵-۱.۰ mm at ۳۵ °C; poor cell-to-PCM contact adds ~۰.۳-۰.۷ mm. Because mass scales nearly linearly with thickness, a small guard (۰.۲-۰.۵ mm) is preferable to blanket oversizing. The deliverable is a one-page chart and short lookup table translating transient behavior into defensible early-stage sizing.

کلیدواژه ها:

Phase-change material (PCM) ، Prismatic battery module ، Thermal management ، Stop-and-go duty ، Design chart