Orthogonal experimental-based thermal management design and simulation optimization of a liquid-cooled battery module
Year: 2025
Type: article
Abstract: 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 ( T max ) and the maximum temperature difference (Δ T min ) 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 T max 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.
Source: Scientific Reports
Authors: Zhe-hui Niu, Kai-ge Pang, Bin-bin Pang, Shuai Wang
Institution: Henan University of Urban Construction
Language: English
Subfield: Automotive Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: gold
Estimated APC paid: $2,690
OpenAlex ID: W4414602849