Orthogonal experimental-based thermal management design and simulation optimization of a liquid-cooled battery module
Zhe-Hui Niu1, Kai-Ge Pang2, Bin-Bin Pang1
1Henan University of Urban Construction, Henan, China.
Scientific Reports
|September 30, 2025
Summary
Optimizing serpentine-channel cold plates for lithium-ion batteries involves precise geometry and coolant flow. This research identifies ideal configurations to minimize battery module temperature and thermal differences, enhancing safety and performance.
Area of Science:
- Thermal Management
- Battery Engineering
- Computational Fluid Dynamics
Background:
- High-capacity lithium-ion batteries require effective thermal management to ensure safety and longevity.
- Thermal inhomogeneity in battery modules can lead to performance degradation and reduced lifespan.
- Serpentine-channel cold plates are a promising solution for liquid cooling in battery systems.
Purpose of the Study:
- To systematically evaluate the thermal performance of serpentine-channel cold plates in high-capacity Li-ion battery modules.
- To identify optimal cooling configurations by analyzing geometric parameters and coolant flow rate.
- To determine the impact of coolant temperature on battery module thermal performance.
Main Methods:
- Orthogonal experimental design was employed to systematically vary parameters.
- STAR-CCM+ computational fluid dynamics (CFD) simulations were utilized for thermal analysis.
- Key performance indicators such as maximum temperature (Tmax) and maximum temperature difference (ΔTmin) were evaluated.
Main Results:
- Optimal cooling configuration achieved with a channel depth of 3 mm, channel width of 28 mm, and coolant flow rate of 2.826 L/min.
- A linear reduction of 2°C in Tmax was observed for every 2°C decrease in coolant temperature within the 16°C to 26°C range.
- The study successfully minimized both Tmax and ΔTmin of the battery module.
Conclusions:
- Precise design of serpentine-channel cold plate geometry is crucial for effective thermal management.
- Active adjustment of coolant temperature significantly impacts battery module thermal performance.
- Optimized cooling strategies can effectively mitigate thermal inhomogeneity in large-format battery systems.
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