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<p>This study addresses the growing demand for high-efficiency battery thermal management systems (BTMS) in the electric-vehicle (EV) sector. A cylindrical 21,700 lithium-ion cell was investigated to elucidate its heat-generation mechanisms and evaluate a hybrid cooling strategy integrating annular fins, phase-change material (PCM), and forced air. The heat‐dissipation module comprises a 2&#xa0;mm-thick ring of fins conformally wrapped around the cell and three Z-shaped air channels (each 34&#xa0;mm × 4&#xa0;mm), with PCM filling the void between fin and cell. Three distinct inlet–outlet configurations were tested to optimize airflow distribution, which was apportioned at 3&#xa0;m/s, 3&#xa0;m/s, and 4&#xa0;m/s among the channels. Although end-cell hotspots persisted in all cases, the single-channel fin–PCM–air system reduced the peak cell temperature to 40&#xa0;°C, 7&#xa0;°C below that achieved by conventional air cooling. The multi-channel design further lowered both the maximum temperature and thermal nonuniformity, decreasing energy consumption by 59.43% at equivalent temperature targets. Under a 3&#xa0;C discharge rate, the optimized system maintained a maximum cell temperature of 36.93&#xa0;°C, this improvement can enhance the lifecycle of the battery.</p>

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Numerical simulation of airflow distribution in battery pack cooling systems with optimized channel design

  • 期刊论文

  • 发表日期：

    2025年6月13日

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  • Jianguo Ye,
  • Chengtao Zhang,
  • Weiguang Zheng,
  • Jingfei Chen,
  • Jirong Qin,
  • Zhaohui Peng

摘要

This study addresses the growing demand for high-efficiency battery thermal management systems (BTMS) in the electric-vehicle (EV) sector. A cylindrical 21,700 lithium-ion cell was investigated to elucidate its heat-generation mechanisms and evaluate a hybrid cooling strategy integrating annular fins, phase-change material (PCM), and forced air. The heat‐dissipation module comprises a 2 mm-thick ring of fins conformally wrapped around the cell and three Z-shaped air channels (each 34 mm × 4 mm), with PCM filling the void between fin and cell. Three distinct inlet–outlet configurations were tested to optimize airflow distribution, which was apportioned at 3 m/s, 3 m/s, and 4 m/s among the channels. Although end-cell hotspots persisted in all cases, the single-channel fin–PCM–air system reduced the peak cell temperature to 40 °C, 7 °C below that achieved by conventional air cooling. The multi-channel design further lowered both the maximum temperature and thermal nonuniformity, decreasing energy consumption by 59.43% at equivalent temperature targets. Under a 3 C discharge rate, the optimized system maintained a maximum cell temperature of 36.93 °C, this improvement can enhance the lifecycle of the battery.