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The purpose of a battery thermal management system (BTMS) is to maintain the battery safety and efficient use as well as ensure the battery temperature is within the safe operating range. The traditional air-cooling-based BTMS not only needs extra power, but it could also not meet the demand of new lithium-ion battery (LIB) packs with high energy density, while liquid cooling BTMS requires complex devices to ensure the effect. Therefore, phase change materials (PCMs)-based BTMS is becoming the trend. By using PCMs to absorb heat, the temperature of a battery pack could be kept within the normal operating range for a long time without using any external power. PCMs could greatly improve the heat dissipation efficiency of BTMS by combining with fillers such as expanded graphite (EG) and metal foam for their high thermal conductivity or coordinating with fins. In addition, PCMs could also be applied in construction materials, solar thermal recovery, textiles and other fields. Herein, a comprehensive review of the PCMs applied in thermal storage devices, especially in BTMS, is provided. In this work, the literature concerning current issues have been reviewed and summarized, while the key challenges of PCM application have been pointed out. This review may bring new insights to the PCM application.

HighlightsThis review delves into the intricate relationship between thermal models, function-oriented design principles, and practical applications in personal radiative thermal management (PRTM).It provides an in-depth discussion on design strategies for radiative cooling, heating, and dual-mode modulating textiles, offering practical insights for application.It offers a thorough examination of the prospects and challenges of PRTM textiles, proposing potential solutions and future directions for the field.Maintaining thermal comfort within the human body is crucial for optimal health and overall well-being. By merely broadening the set-point of indoor temperatures, we could significantly slash energy usage in building heating, ventilation, and air-conditioning systems. In recent years, there has been a surge in advancements in personal thermal management (PTM), aiming to regulate heat and moisture transfer within our immediate surroundings, clothing, and skin. The advent of PTM is driven by the rapid development in nano/micro-materials and energy science and engineering. An emerging research area in PTM is personal radiative thermal management (PRTM), which demonstrates immense potential with its high radiative heat transfer efficiency and ease of regulation. However, it is less taken into account in traditional textiles, and there currently lies a gap in our knowledge and understanding of PRTM. In this review, we aim to present a thorough analysis of advanced textile materials and technologies for PRTM. Specifically, we will introduce and discuss the underlying radiation heat transfer mechanisms, fabrication methods of textiles, and various indoor/outdoor applications in light of their different regulation functionalities, including radiative cooling, radiative heating, and dual-mode thermoregulation. Furthermore, we will shine a light on the current hurdles, propose potential strategies, and delve into future technology trends for PRTM with an emphasis on functionalities and applications.

HighlightsThe state-of-the-art progress of flexible thermally conductive films with ultrahigh in-plane isotropic thermal conductivity (k) and potential application are summarized.The heat transfer mechanism, processing methods to enhance k, optimization strategies to reduce interface thermal resistance of flexible thermally conductive films are reviewed.The limitations and opportunities for the future development of flexible thermally conductive films are proposed.Effective thermal management is quite urgent for electronics owing to their ever-growing integration degree, operation frequency and power density, and the main strategy of thermal management is to remove excess energy from electronics to outside by thermal conductive materials. Compared to the conventional thermal management materials, flexible thermally conductive films with high in-plane thermal conductivity, as emerging candidates, have aroused greater interest in the last decade, which show great potential in thermal management applications of next-generation devices. However, a comprehensive review of flexible thermally conductive films is rarely reported. Thus, we review recent advances of both intrinsic polymer films and polymer-based composite films with ultrahigh in-plane thermal conductivity, with deep understandings of heat transfer mechanism, processing methods to enhance thermal conductivity, optimization strategies to reduce interface thermal resistance and their potential applications. Lastly, challenges and opportunities for the future development of flexible thermally conductive films are also discussed.

With the development of microelectronic devices having miniaturized and integrated electronic components, an efficient thermal management system with lightweight materials, which have outstanding thermal conductivity and processability, is becoming increasingly important. Recently, the use of polymer-based thermal management systems has attracted much interest due to the intrinsic excellent properties of the polymer, such as the high flexibility, low cost, electrical insulation, and excellent processability. However, most polymers possess low thermal conductivity, which limits the thermal management applications of them. To address the low thermal conduction of the polymer materials, many kinds of thermally conductive fillers have been studied, and the carbon-based polymer composite is regarded as one of the most promising materials for the thermal management of the electric and electronic devices. In addition, the next generation electronic devices require composite materials with various additional functions such as flexibility, low density, electrical insulation, and oriented heat conduction, as well as ultrahigh thermal conductivity. In this review, we introduce the latest papers on thermally conductive polymer composites based on carbon fillers with sophisticated structures to meet the above requirements. The topic of this review paper consists of the following four contents. First, we introduce the design of a continuous three-dimensional network structure of carbon fillers to reduce the thermal resistance between the filler–matrix interface and individual filler particles. Second, we discuss various methods of suppressing the electrical conductivity of carbon fillers in order to manufacture the polymer composites that meet both the electrical insulation and thermal conductivity. Third, we describe a strategy for the vertical alignment of carbon fillers to improve the through-plane thermal conductivity of the polymer composite. Finally, we briefly mention the durability of the thermal conductivity performance of the carbon-based composites. This review presents key technologies for a thermal management system of next-generation electronic devices.

HighlightsThe phase change materials possess conformable configuration to the structure of Li-ion batteries in macro-scale and multidirectional thermal pathways for rapid and uniform heat transfer in micro-scale.Hierarchically structured phase change materials achieve dual-mode thermal management ability for heating and cooling Li-ion batteries.Excellent practical battery thermal management performance was verified by 18,650 Li-ion batteries in both cold and hot environments.Phase change materials (PCMs) are expected to achieve dual-mode thermal management for heating and cooling Li-ion batteries (LIBs) according to real-time thermal conditions, guaranteeing the reliable operation of LIBs in both cold and hot environments. Herein, we report a liquid metal (LM) modified polyethylene glycol/LM/boron nitride PCM, capable of dual-mode thermal managing the LIBs through photothermal effect and passive thermal conduction. Its geometrical conformation and thermal pathways fabricated through ice-template strategy are conformable to the LIB’s structure and heat-conduction characteristic. Typically, soft and deformable LMs are modified on the boron nitride surface, serving as thermal bridges to reduce the contact thermal resistance among adjacent fillers to realize high thermal conductivity of 8.8 and 7.6 W m−1 K−1 in the vertical and in-plane directions, respectively. In addition, LM with excellent photothermal performance provides the PCM with efficient battery heating capability if employing a controllable lighting system. As a proof-of-concept, this PCM is manifested to heat battery to an appropriate temperature range in a cold environment and lower the working temperature of the LIBs by more than 10 °C at high charging/discharging rate, opening opportunities for LIBs with durable working performance and evitable risk of thermal runaway.

HighlightsThe first assembled flexible phase change nonwoven is reported by wet-spinning.The unprecedented thermal properties of such flexible phase change nonwoven are achieved.Such phase change nonwoven is highly applicable for mask and cloth intelligent temperature control.Phase change materials have a key role for wearable thermal management, but suffer from poor water vapor permeability, low enthalpy value and weak shape stability caused by liquid phase leakage and intrinsic rigidity of solid–liquid phase change materials. Herein, we report for the first time a versatile strategy for designed assembly of high-enthalpy flexible phase change nonwovens (GB-PCN) by wet-spinning hybrid graphene-boron nitride (GB) fiber and subsequent impregnating paraffins (e.g., eicosane, octadecane). As a result, our GB-PCN exhibited an unprecedented enthalpy value of 206.0 J g−1, excellent thermal reliability and anti-leakage capacity, superb thermal cycling ability of 97.6% after 1000 cycles, and ultrahigh water vapor permeability (close to the cotton), outperforming the reported PCM films and fibers to date. Notably, the wearable thermal management systems based on GB-PCN for both clothing and face mask were demonstrated, which can maintain the human body at a comfortable temperature range for a significantly long time. Therefore, our results demonstrate huge potential of GB-PCN for human-wearable passive thermal management in real scenarios.

HighlightsThe flexible composite film presents ultrahigh thermal conductivity and good thermal management performance in electronic devices.An original “self-modified nanointerface” strategy is used to reduce the interfacial thermal resistance between boron nitride and the polymer matrix.The ideal phonon spectrum matching between boron nitride nanocrystals and fillers as well as the strong interaction between self-modified fillers and the polymer matrix are the two major contributors to decrease the interfacial thermal resistance.While boron nitride (BN) is widely recognized as the most promising thermally conductive filler for rapidly developing high-power electronic devices due to its excellent thermal conductivity and dielectric properties, a great challenge is the poor vertical thermal conductivity when embedded in composites owing to the poor interfacial interaction causing severe phonon scattering. Here, we report a novel surface modification strategy called the “self-modified nanointerface” using BN nanocrystals (BNNCs) to efficiently link the interface between BN and the polymer matrix. Combining with ice-press assembly method, an only 25 wt% BN-embedded composite film can not only possess an in-plane thermal conductivity of 20.3 W m−1 K−1 but also, more importantly, achieve a through-plane thermal conductivity as high as 21.3 W m−1 K−1, which is more than twice the reported maximum due to the ideal phonon spectrum matching between BNNCs and BN fillers, the strong interaction between the self-modified fillers and polymer matrix, as well as ladder-structured BN skeleton. The excellent thermal conductivity has been verified by theoretical calculations and the heat dissipation of a CPU. This study provides an innovative design principle to tailor composite interfaces and opens up a new path to develop high-performance composites.

The rapid improvement in the running speed, transmission efficiency, and power density of miniaturized devices means that multifunctional flexible composites with excellent thermal management capability and high electromagnetic interference (EMI) shielding performance are urgently required. Here, inspired by the fibrous pathways of the human nervous system, a “core-sheath” fibers structured strategy was proposed to prepare thermoplastic polyurethane/polydopamine/carbon nanotube (TPU/PDA/CNT) composites film with thermal management capability and EMI shielding performance. Firstly, TPU@PDA@CNT fibers with CNT shell were prepared by a facile polydopamine-assisted coating on electrospun TPU fibers. Subsequently, TPU/PDA/CNT composites with three-dimensional (3D) fibrous CNT “tracks” are obtained by a hot-pressing process, where CNTs distributed on adjacent fibers are compactly contacted. The fabricated TPU/PDA/CNT composites exhibit a high in-plane thermal conductivity (TC) of 9.6 W/(m·K) at low CNT loading of 7.6 wt.%. In addition, it also presents excellent mechanical properties and excellent EMI shielding effectiveness of 48.3 dB as well as multi-source driven thermal management capabilities. Hence, this study provides a simple yet scalable technique to prepare composites with advanced thermal management and EMI shielding performance to develop new-generation wireless communication technologies and portable intelligent electronic devices.

The current paper is focused on the conceptual design of a thermal management system with a liquid working medium for a commuter hybrid-electric aircraft, featuring a series propulsion configuration. Regarding the system’s architecture, parametric analyses are conducted, by altering the number of heat exchangers. To clarify, a centralised and a decentralised thermal management system architecture are examined. Furthermore, a computational model calculates the temperatures during the system’s operation and the required coolant mass flows to sufficiently cool all the compartments. Subsequently, the required heat exchanger surface is determined and the weight of each compartment that comprises the thermal management system can be calculated. It is worth noting, that the compartments’ cold plate weight is integrated. The results indicate that the decentralised configuration results in lower temperature fields for all components compared to the centralised configuration. However, the latter weighs 32.2% lower at 158.22kg while the decentralised configuration weighs 233.48kg.

Various factors affect the interfacial thermal resistance (ITR) between two materials, making ITR prediction a high-dimensional mathematical problem. Machine learning is a cost-effective method to address this. Here, we report ITR predictive models based on experimental data. The physical, chemical, and material properties of ITR are categorized into three sets of descriptors, and three algorithms are used for the models. Those descriptors assist the models in reducing the mismatch between predicted and experimental values and reaching high predictive performance of 96%. Over 80,000 material systems composed of 293 materials were inputs for predictions. Among the top-100 high-ITR predictions by the three different algorithms, 25 material systems are repeatedly predicted by at least two algorithms. One of the 25 material systems, Bi/Si achieved the ultra-low thermal conductivity in our previous work. We believe that the predicted high-ITR material systems are potential candidates for thermoelectric applications. This study proposed a strategy for material exploration for thermal management by means of machine learning.