This paper investigates three different configurations of a hybrid battery thermal management system (BTMS) using phase change material (PCM) as passive and air coolant as active cooling system. The PCM surrounded the battery cell is encapsulated in three different vessel cross-sections as circular, rectangular, and hexagonal with equal volumes. Each of these BTMS consists of 12 Sony 18650 batteries with the same pack holder. The thermal management of the battery pack is examined in the course of different charging and discharging rates. Results reveal that the thermal performance of both hexagonal and circular PCM vessels show generally the same behavior. Utilization the latent heat as the passive coolant in the battery thermal management is the strong point, which results show that the circular PCM configuration is the best one. However, in the high rate of charging or discharging condition, the uniform air channel around the rectangular shape makes a more efficient cooling compared to the other arrangements. •Investigate on the hybrid active-passive battery thermal management system (BTMS) is the main objective.•Phase change material (PCM) as passive and air coolant as an active cooling system are considered.•A transient numerical study conducted on the three different PCM encapsulation shape.•Uniform shape of PCM encapsulation (circular shape) is the thermal efficient in the passive cooling.•Uniform air channel, rectangular shape of PCM encapsulation is thermal efficient in the active cooling.