Applied Thermal Engineering最新文献_第8页

Physics-guided genetic algorithm for optimization of multi-jet impingement cooling 多射流冲击冷却优化的物理导向遗传算法

IF 6.9 2区工程技术 Q2 ENERGY & FUELS

Applied Thermal Engineering

Pub Date : 2026-01-25 DOI: 10.1016/j.applthermaleng.2026.129889

Yonghun Kim , Haeun Lee , Seokwon Jeong , Nana Kang , Changwoo Han , Dongmin Shin , Hyoungsoon Lee

Efficient thermal management is essential for maximizing the performance and reliability of power semiconductor devices, particularly in data centers, electric vehicles, drive motors, and photovoltaic systems. Multi-jet impingement cooling has emerged as a promising solution, offering enhanced heat transfer from thinning boundary layers, and localized cooling capabilities, but its optimization remains challenging due to the complexity and high dimensionality of the design parameter space. This study develops machine learning framework coupled with a genetic algorithm to efficiently predict and optimize the thermal and hydraulic performance of multi-jet impingement cooling. We trained scalar and multimodal machine learning models using comprehensive computational fluid dynamics simulations, incorporating physical principles to enhance predictive accuracy. As a result, prediction errors decreased substantially, from 408.2% to 10.3% for pressure drop and from 25.9% to 3.7% for maximum temperature. Compared to conventional computational approaches, our proposed methodology significantly reduces computational effort and accelerates the identification of optimal cooling configurations. This study presents a robust and efficient strategy for advancing thermal management solutions critical to next generation high power semiconductor applications.

高效的热管理对于最大限度地提高功率半导体器件的性能和可靠性至关重要，特别是在数据中心、电动汽车、驱动电机和光伏系统中。多喷流碰撞冷却已经成为一种很有前途的解决方案，可以通过变薄的边界层增强热传递，并具有局部冷却能力，但由于设计参数空间的复杂性和高维性，其优化仍然具有挑战性。本研究开发了结合遗传算法的机器学习框架，以有效地预测和优化多射流冲击冷却的热性能和水力性能。我们使用综合计算流体动力学模拟来训练标量和多模态机器学习模型，并结合物理原理来提高预测准确性。结果，预测误差大幅降低，压降预测误差从408.2%降至10.3%，最高温度预测误差从25.9%降至3.7%。与传统的计算方法相比，我们提出的方法显着减少了计算工作量，并加速了最佳冷却配置的识别。本研究为推进下一代高功率半导体应用的关键热管理解决方案提供了一个强大而高效的策略。

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引用次数: 0

Effects of ozone addition on lean-burn ammonia-hydrogen combustion in spark-ignition engine 臭氧添加对火花点火发动机贫燃氨氢燃烧的影响

IF 6.9 2区工程技术 Q2 ENERGY & FUELS

Applied Thermal Engineering

Pub Date : 2026-01-24 DOI: 10.1016/j.applthermaleng.2026.129926

Xuanjie Cui , Juanya Shen , Qingxuan Wang , Peng Liu , Zhen Huang , Dong Han

This study examines the effects of ozone addition on the combustion and emissions of spark-ignition ammonia‑hydrogen engines operating under lean-burn conditions, addressing challenges such as low flame propagation speed and high ignition energy in ammonia combustion. Utilizing three-dimensional numerical simulations, the research evaluates the impact of varied ozone concentrations (1.0–2.0%) on engine performance and emissions, and explores the ultra-lean combustion limit at a high ozone concentration of 2.0%. The results show that ozone addition enhances the lean combustion process. As the ozone concentration increases, the indicated mean effective pressure and indicated thermal efficiency initially increase and then decline. Ozone addition extends the lean combustion limit of the ammonia‑hydrogen engine, reduces the risk of engine knocking, decreases heat transfer losses, and enhances thermal efficiency. Promising performance is observed at an equivalence ratio of 0.3 with 2.0% ozone, resulting in higher indicated thermal efficiency and lower total pollutant emissions under the investigated conditions.

本研究考察了臭氧添加对在稀燃条件下运行的火花点火式氨氢发动机燃烧和排放的影响，解决了氨燃烧中火焰传播速度低和点火能量高的挑战。利用三维数值模拟技术，研究了不同臭氧浓度（1.0-2.0%）对发动机性能和排放的影响，并探索了高浓度臭氧浓度为2.0%时的超稀薄燃烧极限。结果表明，臭氧的加入对稀薄燃烧过程有促进作用。随着臭氧浓度的增加，指示平均有效压力和指示热效率先增大后减小。臭氧的加入延长了氨氢发动机的稀薄燃烧极限，降低了发动机爆震的风险，减少了传热损失，提高了热效率。当臭氧的当量比为0.3，臭氧的当量比为2.0%时，表明热效率较高，总污染物排放量较低。

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引用次数: 0

Performance evaluation of a vacuum tube-based direct-expansion solar-assisted moderate and high temperature heat pump 基于真空管的直接膨胀太阳能辅助中高温热泵的性能评价

IF 6.9 2区工程技术 Q2 ENERGY & FUELS

Applied Thermal Engineering

Pub Date : 2026-01-24 DOI: 10.1016/j.applthermaleng.2026.129925

Xiaohui Yu , Qing Xu , Xiangyi Kong , Zhonglian Guo , Bin Yang , Shuo Ma

The Direct-expansion solar-assisted moderate and high temperature heat pump (DX-SAMHTHP) system can elevate the temperature of the low-grade solar heat to a higher and more useful level. This paper proposed a vacuum tube-based DX-SAMHTHP system providing 70–90 °C heat. Then, an experimental bench was setup and tested under various conditions. Moreover, the energy and exergy performances of such proposed system were investigated and evaluated. The results show that as the solar radiation intensity increases from 519.64 W/m² to 1137.02 W/m², the system COP rises by 11.37% (5.19–5.78), while the collector efficiency drops by 34.38% (0.96–0.63). When the heat output temperature increases from 70 °C to 90 °C, the system COP and exergy destruction decrease from 5.69 to 5.48, 1404.92 W to 1336.00 W, respectively. With the ambient temperature increases from 27.76 °C to 34.52 °C, the system COP increases from 5.6 to 5.87. Additionally, the heating power and COP of the system with the collector-evaporator area of 3 m² is 2221.98 W and 6.13, which are 71.52%, and 5.92% higher than the collector-evaporator area of 1.5 m². These results indicate that the proposed DX-SAMHTHP system can provide 70–90 °C heat and operate with high performance.

直接膨胀式太阳能辅助中高温热泵（DX-SAMHTHP）系统可以将低品位太阳能热的温度提升到更高、更有用的水平。本文提出了一种基于真空管的DX-SAMHTHP系统，提供70-90°C的热量。在此基础上搭建了实验平台，并进行了各种条件下的实验。并对该系统的能量和火用性能进行了研究和评价。结果表明：当太阳辐射强度从519.64 W/m2增加到1137.02 W/m2时，系统COP提高11.37%(5.19 ~ 5.78)，集热器效率下降34.38% (0.96 ~ 0.63)；当输出热量温度从70℃升高到90℃时，系统COP从5.69降低到5.48，火用破坏从1404.92 W降低到1336.00 W。随着环境温度由27.76℃升高到34.52℃，系统COP由5.6升高到5.87。集热器-蒸发器面积为3 m2时，系统的供热功率为2221.98 W， COP为6.13 W，分别比集热器-蒸发器面积为1.5 m2时高71.52%和5.92%。这些结果表明，所提出的DX-SAMHTHP系统可以提供70-90°C的热量，并具有高性能。

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引用次数: 0

Effects of axial length on two-phase n-decane/air rotating detonation chamber 轴向长度对两相正癸烷/空气旋转爆轰室的影响

IF 6.9 2区工程技术 Q2 ENERGY & FUELS

Applied Thermal Engineering

Pub Date : 2026-01-24 DOI: 10.1016/j.applthermaleng.2026.129961

Xiaofeng Shao , Qiang Wang , Yongbao Liu , Shuyong Liu , Youhong Yu , Ningbo Zhao , Hongtao Zheng

In this paper, two-phase rotating detonation combustion fueled by n-decane/air mixtures is simulated using Eulerian-Lagrangian method. Three-dimensional non-premixed rotating detonation chamber (RDC) with various axial lengths (45 mm, 65 mm and 85 mm) is considered. The effects of axial length on the flow filed structures, propagation characteristics and RDC performance are discussed. Numerical results demonstrate that axial length of has a significant influence on combustion product expansion, propagation stability of rotating detonation wave (RDW), and pressure gain performance of RDC. Specifically, restricting axial length of RDC induces incomplete expansion of combustion products. It is characterized by elevated pre-detonation pressure and temperature, a dominant deflagration combustion mode, and the collision and regeneration between oblique shock wave (OSW) and slip line (SL). A predictive formula for the relationship between RDC length and RDW height is established. The critical RDC length is 33 mm. Furthermore, as the axial length of RDC decreases, the intensity of the RDW weakens, the speed increases, the pressure peak first decreases and then increases, and the highest detonation stability occurs at 65 mm. The operating boundary of RDC is not affected by the axial length, and the mode transition boundary becomes narrower at larger axial length. Finally, shorter axial length of RDC can suppress the development of OSW, reduce additional entropy increase, and increase the total pressure gain of RDC from −0.14 to 0.18. The novelty of this study lies in establishing a predictive relationship between RDC length and RDW height, clarifying the operational boundary and pressure gain performance of RDC, thereby providing direct theoretical support for two-phase RDC design.

本文采用欧拉-拉格朗日方法模拟了正癸烷/空气混合燃料的两相旋转爆轰燃烧。考虑了不同轴向长度（45mm、65mm和85mm）的三维非预混旋转爆震室（RDC）。讨论了轴向长度对流场结构、传播特性和RDC性能的影响。数值计算结果表明，轴向长度对燃烧产物膨胀、旋转爆震波传播稳定性以及旋转爆震波的压力增益性能有显著影响。具体来说，限制RDC轴向长度会导致燃烧产物的不完全膨胀。其特点是爆轰前压力和温度升高，燃烧方式以爆燃为主，斜激波（OSW）与滑线（SL）碰撞再生。建立了RDC长度与RDW高度关系的预测公式。RDC临界长度为33mm。随着RDC轴向长度的减小，RDC强度减弱，速度增大，压力峰值先减小后增大，爆轰稳定性在65 mm处达到最高。RDC的工作边界不受轴向长度的影响，轴向长度越大，模态过渡边界越窄。最后，较短的RDC轴向长度可以抑制OSW的发展，减少附加熵的增加，使RDC的总压增益从−0.14提高到0.18。本研究的新颖之处在于建立了RDC长度与RDW高度之间的预测关系，明确了RDC的运行边界和压力增益性能，从而为两相RDC设计提供了直接的理论支持。

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引用次数: 0

Rapid identification of surface damage in ablative materials via inversion of isotherm dynamics 利用等温动力学反演快速识别烧蚀材料表面损伤

IF 6.9 2区工程技术 Q2 ENERGY & FUELS

Applied Thermal Engineering

Pub Date : 2026-01-24 DOI: 10.1016/j.applthermaleng.2026.129917

Yuhang Yin, Tingting Wu, Hongli Ji, Chao Zhang, Chongcong Tao, Jinhao Qiu

Due to the highly complex thermal response associated with ablation, numerical analysis of this processes usually incurs substantial computational cost and nonlinearity, posing a challenge for the quantitative identification of surface damage in ablative thermal protection systems. To address this issue, a novel moving temperature boundary method is proposed to significantly simplify the computational complexity of the forward ablation model, thereby enabling rapid and accurate damage inversion. Unlike conventional inverse approaches that construct static damage directly on the model surface, the proposed method reconstructs the dynamic evolution of internal isotherms to extract damage-related information. By selecting an isotherm at an appropriate temperature, high-complexity regions associated with pyrolysis can be excluded from the computational domain, leaving only the virgin material governed by the standard heat conduction equation. Compared with traditional methods, the new approach achieves a 99.09% reduction in computation time. Moreover, excluding high-complexity regions reduces the nonlinearity of the model, thereby enhancing the robustness of the inverse solution against measurement noise. Both numerical simulations and experiments validate the effectiveness and reliability of the method. The results demonstrate that the moving temperature boundary method offers a novel and efficient framework for damage detection and health monitoring of aerospace thermal protection systems.

由于与烧蚀相关的热响应非常复杂，对烧蚀过程进行数值分析通常会产生大量的计算成本和非线性，这对烧蚀热保护系统表面损伤的定量识别提出了挑战。为了解决这一问题，提出了一种新的移动温度边界方法，大大简化了正烧蚀模型的计算复杂度，从而实现了快速准确的损伤反演。与传统的直接在模型表面构造静态损伤的逆方法不同，该方法重构了内部等温线的动态演化，提取损伤相关信息。通过选择合适温度下的等温线，可以将与热解相关的高复杂性区域排除在计算域之外，只留下由标准热传导方程控制的原始材料。与传统方法相比，新方法的计算时间缩短了99.09%。此外，排除高复杂度区域降低了模型的非线性，从而增强了反解对测量噪声的鲁棒性。数值模拟和实验验证了该方法的有效性和可靠性。结果表明，移动温度边界法为航天热防护系统的损伤检测和健康监测提供了一种新颖有效的框架。

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引用次数: 0

Multi-objective optimization and experimental validation of a conformal battery cooling block 保形电池冷却块的多目标优化与实验验证

IF 6.9 2区工程技术 Q2 ENERGY & FUELS

Applied Thermal Engineering

Pub Date : 2026-01-24 DOI: 10.1016/j.applthermaleng.2026.129898

Seyda Ozbektas , Bilal Sungur , Furkan Mumcu , Alirıza Kaleli

This study presents the design optimization, numerical modeling, and experimental validation of a novel conformal liquid cooling system developed for cylindrical lithium-ion battery modules. A genetic algorithm was employed to optimize the geometrical parameters of internal and external conformal cooling channels based on the criteria of maximum cell temperature (T_max), maximum temperature difference (ΔT_max), and pressure drop (ΔP). The final design, manufactured via additive methods, was integrated into a 3 × 3 Aspilsan INR18650A28 battery module and tested experimentally under a 5C discharge rate and ≈0.0083 kg/s flow rate. Experimental results demonstrated effective thermal regulation, with a maximum temperature (T_max) of 27.44 °C. Numerical simulations under the same conditions yielded a T_max of 25.69 °C, indicating a strong correlation with experimental data. Additional numerical studies based on the MSMD model revealed that the system maintained temperatures below 25 °C for 5C, ∼31 °C for 7C, and below 40 °C for 9C, confirming robust thermal control across a range of operating conditions. Furthermore, variations in coolant inlet temperature (5 °C, 15 °C, and 25 °C) significantly affected average cell temperatures but had minimal impact on thermal uniformity, with ΔT_max remaining below 0.51 °C in all scenarios. Compared to existing BTMS designs in the literature, the proposed conformal system delivered superior performance in both T_max and ΔT_max metrics under high discharge rates. These results validate the effectiveness and manufacturability of conformal cooling as a next-generation battery thermal management strategy for high-performance and compact electric vehicle applications.

本研究介绍了一种用于圆柱形锂离子电池模块的新型保形液冷系统的设计优化、数值建模和实验验证。采用遗传算法，以最大胞体温度（Tmax）、最大温差（ΔTmax）和压降（ΔP）为准则，对内外保形冷却通道的几何参数进行优化。最终设计通过增材制造，集成到3 × 3 Aspilsan INR18650A28电池模块中，并在5C放电率和≈0.0083 kg/s流速下进行实验测试。实验结果表明，热调节有效，最高温度（Tmax）为27.44℃。在相同条件下的数值模拟结果显示Tmax为25.69°C，与实验数据有较强的相关性。基于MSMD模型的其他数值研究表明，该系统在5C时温度低于25°C，在7C时温度低于31°C，在9C时温度低于40°C，证实了在一系列操作条件下的强大热控制。此外，冷却剂进口温度（5°C、15°C和25°C）的变化会显著影响电池的平均温度，但对热均匀性的影响最小，在所有情况下ΔTmax都保持在0.51°C以下。与文献中现有的BTMS设计相比，在高放电率下，所提出的保形系统在Tmax和ΔTmax指标上都具有优越的性能。这些结果验证了保形冷却作为高性能和紧凑型电动汽车应用的下一代电池热管理策略的有效性和可制造性。

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引用次数: 0

Tube plugging effects on the thermal–hydraulic characteristics of a CAP1400 steam generator with a three-dimensional primary–secondary coupled heat-transfer model 基于三维主-二次耦合传热模型的CAP1400蒸汽发生器堵管对热工特性的影响

IF 6.9 2区工程技术 Q2 ENERGY & FUELS

Applied Thermal Engineering

Pub Date : 2026-01-24 DOI: 10.1016/j.applthermaleng.2026.129935

Lanqing Qiao , Jianyu Tan , Qingzhi Lai , Wei Zeng , Junming Zhao

In steam generators (SGs), heat transfer tubes are about 1 mm thick and operate under severe conditions. Therefore, preventive tube plugging is routinely applied to limit tube failure risk. However, most studies of SG tube plugging still rely on one-dimensional system codes, which cannot capture the impact of plugged-tube distribution on three-dimensional thermal–hydraulic performance. In this study, a three-dimensional primary–secondary coupled heat-transfer model is developed for tube plugging conditions. After validation, the effects of plugging location and plugging ratio on the thermal–hydraulic characteristics of the CAP1400 SG are systematically investigated. The tube bundle region is modeled as a porous medium, and the plugged tubes are represented in the cross-section by an annular region. A mesh-mapping method is proposed to enable robust coupled heat-transfer calculations between the two nonconformal sides. The results show that SG thermal power and outlet steam mass flow decrease as the plugged region moves outward and as the plugging ratio increases. Tube plugging has little effect on the secondary-side pressure drop, whereas the primary-side pressure drop increases with plugging ratio. At a plugging ratio of 20%, SG thermal power and outlet steam flow decrease by up to 7.20% and 6.43%, respectively, while the primary-side pressure drop increases by up to 36.36% relative to the normal condition. This study conducts the first systematic numerical study of tube plugging in the CAP1400 SG. The results support the safe operation of CAP1400 units and provide a modelling framework for future digital-twin studies of nuclear power systems.

在蒸汽发生器（SGs）中，传热管约为1mm厚，并且在恶劣的条件下运行。因此，预防性堵管通常用于限制管的失效风险。然而，大多数SG管堵塞研究仍然依赖于一维系统代码，无法捕捉堵塞管分布对三维热工性能的影响。本文建立了管道堵塞条件下的三维一次—二次耦合传热模型。验证后，系统研究了封堵位置和封堵比对CAP1400 SG热液特性的影响。管束区域被建模为多孔介质，堵塞的管在横截面上用环形区域表示。提出了一种网格映射方法，实现了两非保形面之间的鲁棒耦合传热计算。结果表明：随着堵塞区域向外移动和堵塞比的增大，SG热功率和出口蒸汽质量流量减小；堵管对二次侧压降影响不大，一次侧压降随堵管比的增大而增大。当封堵比为20%时，SG热功率和出口蒸汽流量分别比正常工况下降7.20%和6.43%，一次侧压降比正常工况增加36.36%。本文首次对cap1400sg的堵管问题进行了系统的数值研究。研究结果支持CAP1400机组的安全运行，并为未来核电系统的数字孪生研究提供建模框架。

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引用次数: 0

Boosting thermo-hydraulic performance in wavy plate-fin heat exchangers through ellipsoidal protrusions/dimples functioning as vortex generators 利用椭球突起/凹窝作为涡发生器提高波浪板翅式换热器的热工性能

IF 6.9 2区工程技术 Q2 ENERGY & FUELS

Applied Thermal Engineering

Pub Date : 2026-01-24 DOI: 10.1016/j.applthermaleng.2026.129945

HaoLong Dong , Chen Gao , Xiang Wu , Mei Su , Kun Zhang , Lin Chen , KeWei Song

The wavy plate-fin heat exchanger (WPFHE) is pivotal in industries like energy and chemical engineering due to its compactness and efficiency. However, further enhancing its thermo-hydraulic performance remains a critical challenge. To enhance the energy utilization efficiency and heat transfer performance of the WPFHE, this study introduces a novel design of wavy fins integrated with ellipsoidal protrusions/dimples, which act as vortex generators to intensify fluid disturbance and secondary flow. A three-dimensional numerical simulation was conducted to evaluate the impact of the protrusion/dimple attack angle (β) on performance. The results show that the use of protrusions/dimples effectively disturbs the fluid flow within the wavy channel, enhances the intensity of secondary flow (Se), and achieves significant heat transfer enhancement. The ellipsoidal protrusions/dimples increase the channel's Se(x,z) by 21.83%–31.54%, and Nu by 3.41%–62.98%, in comparison to the corresponding wavy channel without vortex generators. The channel's thermal performance factor (JF) peaks at 1.473 when the attack angle is optimally set to β = 60°. Compared with the delta-shaped winglet vortex generators typically studied in the literature, the ellipsoidal protrusions/dimples exhibit a maximum increase in JF of 20.24%. The findings of this study serve as a reference for determining the optimal β of ellipsoidal protrusions/dimples in the design of WPFHE. Fitting correlation formulas for Nu, f, and JF are given for chemical industry reference with maximum error values less than ±5%, ±8%, and ± 3%, respectively.

波浪板式翅片换热器（WPFHE）由于其紧凑和高效，在能源和化学工程等行业中发挥着关键作用。然而，进一步提高其热液性能仍然是一个关键的挑战。为了提高WPFHE的能量利用效率和传热性能，本研究引入了一种新型的椭球状突起/凹槽集成波浪鳍的设计，该设计可以作为涡流发生器来加剧流体扰动和二次流动。采用三维数值模拟方法研究了凸/窝攻角（β）对性能的影响。结果表明：利用凸/凹陷有效地干扰了波浪通道内的流体流动，增强了二次流强度（Se），实现了显著的换热强化。椭球状突起/凹陷使通道的Se（x,z）和Nu分别提高了21.83% ~ 31.54%和3.41% ~ 62.98%。当攻角最佳设置为β = 60°时，通道的热性能因子（JF）峰值为1.473。与文献中典型的三角型小涡发生器相比，椭球状突起/凹窝的JF最大增加了20.24%。研究结果可为确定椭圆型凸/凹的最佳β值提供参考。给出了Nu、f和JF的拟合相关公式，供化工行业参考，最大误差分别小于±5%、±8%和±3%。

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引用次数: 0

Research on multi-physics coupled heat transfer enhancement of the tilted solar chimney with phase change material 相变材料倾斜太阳烟囱多物理场耦合强化传热研究

IF 6.9 2区工程技术 Q2 ENERGY & FUELS

Applied Thermal Engineering

Pub Date : 2026-01-24 DOI: 10.1016/j.applthermaleng.2026.129804

Sheng Huang , Zerui Peng , Yongcai Li , Jun Lu , Zhihao Wang , Shihan Deng , Wuyan Li

To enhance the all-weather ventilation performance of solar chimneys, this study developed a numerical model of a tilted solar chimney integrated with phase-change material (PCM-SC) considering the multi-physics coupled heat transfer. The research focused on four critical parameters: tilt angle, heat flux density, air convective boundary conditions, and embedding fins, revealing the thermal and ventilation performance of the PCM-SC under multi-physics coupling effects. Key findings include: under tilt angle of 45°, the SC achieved the maximum ventilation rate (increasing by 30.8% and 12.3% compared to 30° and 60°, respectively), and the PCM acquired optimal phase-change cycle efficiency. Increasing the heat flux by 200 W/m² reduced the melting time of PCM by 27.5% but negligibly influenced on solidification time. Flow field analysis revealed that natural convection intensity evolved nonlinearly during phase change process, peaking at a liquid fraction of 0.6, while solidification exhibited stratified heat transfer characteristics. Air convective boundaries enhanced the heat transfer efficiency in late-stage melting period by 42%. Integrating three bottom fins reduced the melting time by 18.4%, and the improvement stemmed from simultaneously expanding heat transfer area and phase-change interfaces.

为了提高太阳能烟囱的全天候通风性能，本文建立了考虑多物理场耦合传热的相变材料（PCM-SC）倾斜太阳能烟囱的数值模型。研究了倾斜角度、热流密度、空气对流边界条件和埋片4个关键参数，揭示了多物理场耦合作用下PCM-SC的散热和通风性能。主要发现包括：在45°倾角下，SC获得最大通风量（比30°和60°分别增加30.8%和12.3%），PCM获得最佳相变周期效率。增加200 W/m²的热流密度可使PCM的熔化时间缩短27.5%，但对凝固时间的影响微乎其微。流场分析表明，自然对流强度在相变过程中呈非线性变化，在液相分数为0.6时达到峰值，而凝固过程呈现分层传热特征。空气对流边界使熔后期换热效率提高了42%。三个底翅片的集成使熔化时间缩短了18.4%，这主要是由于同时扩大了传热面积和相变界面。

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引用次数: 0

Ignition mechanism induced by circulating current in parallel-connected LiFePO₄ modules and an electro-thermal-flame multidimensional barrier strategy against thermal runaway propagation 循环电流在lifepo_4并联模块中的引燃机理及热失控传播的电热火焰多维阻挡策略

IF 6.9 2区工程技术 Q2 ENERGY & FUELS

Applied Thermal Engineering

Pub Date : 2026-01-24 DOI: 10.1016/j.applthermaleng.2026.129900

Ying Zhang, Jianing Wang, Yongfei Ma, Hang Yu, Binbin Mao

The circulating current generated after thermal runaway (TR) in a parallel-connected battery module significantly exacerbates associated hazards, including easier ignition and faster TR propagation, which received insufficient attention in prior research. This study first reveals the fundamental reason why circulating currents act as a module-level ignition source, and establishes an Electro-Thermal-Flame multidimensional barrier strategy for TR propagation. Parallel configurations increase ignition probability from 0% (open-circuit) to 81.8%, and shorten the TR propagation time between cells by 500 s. When the first cell fell into short-circuited and TR in a local-heated battery module, a high-rate current (∼10C) flows through both cells simultaneously. This current induces Joule heating at the tabs of the adjacent cell, leading to mechanical loosening via thermal expansion (≥660 °C) and internal gas pressure. Arcing and sparks occur due to intermittent contact within the circuit, resulting in initial flame emergence at the tabs of the adjacent cell, igniting the electrolyte vapor. Notably, conventional single-dimension barriers fail to prevent TR propagation under circulating currents. To address this, a multidimensional TR barrier strategy is designed: a coupled approach utilizing aerogel, fusible links, and flame arresters that targets heat transfer, circulating current, and flame heating, respectively. This approach reduced 90% in the conductive heat transfer, 65% in electrical energy transfer, and 53% in flame heating. This integrates Electro-Thermal-Flame three-dimensional barrier system, based on the synergistic mechanism of passive insulation, active fusing, and radiation dissipation, significantly suppresses TR propagation in confined-space parallel modules.

并联电池模块热失控（TR）后产生的循环电流显著加剧了相关危险，包括更容易着火和更快的TR传播，这在以往的研究中没有得到足够的重视。本研究首先揭示了循环电流作为模块级点火源的根本原因，并建立了TR传播的电热火焰多维阻挡策略。并联配置将点火概率从0%（开路）提高到81.8%，并将TR在胞间的传播时间缩短500 s。当第一个电池在局部加热的电池模块中陷入短路和TR时，高速率电流（~ 10C）同时流过两个电池。该电流在相邻电池的标签处引起焦耳加热，通过热膨胀（≥660°C）和内部气体压力导致机械松动。电弧和火花是由于电路内的间歇性接触而发生的，导致相邻电池的标签处出现最初的火焰，点燃电解质蒸气。值得注意的是，传统的一维屏障无法阻止环流下的TR传播。为了解决这个问题，设计了一种多维TR屏障策略：一种利用气凝胶、可熔连接和阻火器的耦合方法，分别针对传热、循环电流和火焰加热。这种方法减少了90%的导热传热，65%的电能传递，53%的火焰加热。该系统集成了电-热-火焰三维屏障系统，基于被动绝缘、主动融合和辐射耗散的协同机制，显著抑制了密闭空间并联模块中的TR传播。

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