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<p>This study systematically evaluates the thermal performance of serpentine-channel cold plates in high-capacity Li-ion battery modules, focusing on geometric parameters (depth/width) and coolant flow rate. Through orthogonal experimental design coupled with <i>STAR-CCM +</i> computational fluid dynamics simulations, we identify optimal cooling configurations. The results indicate that both the maximum temperature (<i>T</i><sub>max</sub>) and the maximum temperature difference (Δ<i>T</i><sub>min</sub>) of the battery module have reached their minimum values with a Liquid-cooling plate channel depth of 3&#xa0;mm, channel width of 28&#xa0;mm, and coolant flow rate of 2.826&#xa0;L/min, and when the coolant temperature is within the range of 16&#xa0;°C to 26&#xa0;°C, a linear reduction in the <i>T</i><sub>max</sub> of 2&#xa0;°C is observed for every 2&#xa0;°C decrease in coolant temperature. The results demonstrate that precise channel geometry design with active coolant temperature adjustment can effectively mitigate thermal inhomogeneity in large-format battery systems.</p>

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Orthogonal experimental-based thermal management design and simulation optimization of a liquid-cooled battery module

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2025年9月29日

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  • Zhe-hui Niu,
  • Kai-ge Pang,
  • Bin-bin Pang,
  • Shuai Wang

摘要

This study systematically evaluates the thermal performance of serpentine-channel cold plates in high-capacity Li-ion battery modules, focusing on geometric parameters (depth/width) and coolant flow rate. Through orthogonal experimental design coupled with STAR-CCM + computational fluid dynamics simulations, we identify optimal cooling configurations. The results indicate that both the maximum temperature (Tmax) and the maximum temperature difference (ΔTmin) of the battery module have reached their minimum values with a Liquid-cooling plate channel depth of 3 mm, channel width of 28 mm, and coolant flow rate of 2.826 L/min, and when the coolant temperature is within the range of 16 °C to 26 °C, a linear reduction in the Tmax of 2 °C is observed for every 2 °C decrease in coolant temperature. The results demonstrate that precise channel geometry design with active coolant temperature adjustment can effectively mitigate thermal inhomogeneity in large-format battery systems.