Optimization of three-layer staggered liquid cooling system for high-rate charging of large cylindrical battery module in electric vehicles
Year: 2025
Type: article
Abstract: Effective thermal management is critical for maintaining safe operating temperatures and minimizing temperature gradients in lithium-ion batteries (LIBs) used in electric vehicles (EVs), particularly under high-rate charging conditions. This study proposes a novel three-layer staggered liquid-cooled pipe (TSLP) system designed for large cylindrical LIBs to enhance heat dissipation efficiency during 4C fast charging. A single-factor analysis was conducted to evaluate the effects of pipe height (h = 14-44 mm), staggered flow layouts (4 configurations), and wall thickness (δ = 0.4-1.0 mm). Key design parameters were identified that minimize the maximum temperature (Tmax) and inter-cell temperature difference (ΔTcell-max). The optimal configuration achieved Tmax=36.17℃ and ΔTcell-max=2.43℃ with: (1) middle-layer pipe height h=34 mm, (2) counter-flow arrangement, and (3) wall thickness δ=0.6 mm. The Box-Behnken design (BBD) optimization was conducted for three factors: ambient temperature (35-45℃), coolant flow rate (0.01-0.05 m/s), and cooling rate (2-4℃/min) during 15-min 4C charging. The optimized results are compared with computational fluid dynamics simulations and experimental tests, demonstrating that the maximum temperature deviation from the experimental tests is within 0.4℃ and the deviation of the maximum temperature difference between LIBs (ΔTcell-max) is within 0.3 ℃. These findings offer a practical and scalable solution for managing heat generation in large cylindrical LIBs under high-rate charging conditions in EVs.
Source: Applied Thermal Engineering
Language: English
Subfield: Automotive Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: hybrid
Estimated APC paid: $3,660
OpenAlex ID: W4414803034