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Numerical Analysis and Multiobjective Optimization of Pin‐Fin Cold Plates for Battery Modules Under Extreme Operating Conditions

Year: 2026
Type: article
Abstract: This study investigates the optimal design parameters and operating conditions of a pin‐fin cold plate to minimize thermal‐runaway risk under a worst‐case scenario (130 A discharge current, 20% state of charge [SOC], 40°C ambient temperature) for EVs. Cold plate thickness was fixed at 3 mm to meet weight constraints. Temperature‐dependent fluid properties were considered to improve simulation accuracy. A novel and scalable Nusselt correlation for pin‐fin cold plates was developed, with an R 2 of 0.982 and a root mean squared error (RMSE) of 0.7078. Through NSGA‐II coupled with regression‐based surrogate models trained on the L25 numerical dataset, the optimum design was obtained with a pin‐fin diameter of 26.31 mm, a volumetric flow rate of 4.66 L/min, and an inlet temperature of 23.12°C. The optimum design achieved a maximum battery contact‐surface temperature of 31.87°C, keeping the battery within the ideal operating range (15°C–35°C) and safety limit (50°C). Compared with the reference Case 1 configuration (Δ T cs = 11.18°C, Δ P = 343.38 Pa), the optimum design reduced Δ T cs to 5.66°C (about 49% improvement), achieving a balanced trade‐off between thermal performance and hydraulic loss at a pressure drop of 1073.87 Pa. The proposed methodology provides a scalable framework to streamline battery thermal management system (BTMS) design.
DOI: 10.1155/er/8734019
Language: English
Open Access status: gold
Estimated APC paid: $2,700
OpenAlex ID: W7204276409
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Cites: 72
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Related to: 10