Hybrid Thermal Management System for Prismatic Lithium‐Ion Batteries Based on Alternating Inlet Flow and Simplified Porous‐Structured Fins

This study introduces a hybrid battery thermal management system (BTMS) for prismatic lithium‐ion batteries, combining a semi‐enclosed liquid cooling plate (S‐ELCP) with alternating inlet channels and simplified porous‐structured fins (SPSF). Validated via experimental electrochemical‐thermal modeling under a 3C discharge rate, the system simultaneously optimizes heat dissipation, temperature uniformity, and hydraulic efficiency. Findings indicate the alternating inlet strategy reduces Inlet‐outlet pressure drop (Δ P ) by 76.9% and significantly improves temperature distribution over single‐inlet baselines. Furthermore, the continuous thermal pathways of the SPSF1 topology provide superior heat removal compared to SPSF2. Parametric optimization reveals that a 0.25 g·s ⁻¹ coolant flow rate and 70.56% fin porosity achieve the ideal balance between thermal conduction and latent heat storage. Under these optimal conditions, the maximum temperature ( T _max ) is restricted to 310.65 K and the maximum temperature difference (Δ T _max ) to 3.48 K—reductions of 5.72 and 5.41 K versus conventional designs—while maintaining a low Δ P of 94.98 Pa. This configuration ensures highly efficient, energy‐saving thermal regulation within a compact footprint.