IDEAS home Printed from https://ideas.repec.org/a/eee/energy/v320y2025ics0360544225009739.html
   My bibliography  Save this article

Passive flow rate regulation and unequally spaced channel based battery thermal management system

Author

Listed:
  • Shi, Chenwei
  • Xu, Jun
  • Guo, Zhechen
  • Wang, Xingzao
  • Mei, Xuesong

Abstract

Lithium-ion batteries (LIBs) used in electric vehicles are susceptible to high temperatures and temperature difference, which can significantly impact their lifespan and safety. To solve these problems, a battery thermal management system (BTMS) comprises an optimized cold plate named unequally spaced channel (USC) and a passive flow regulation structure is proposed. For the USC cold plate, a multi-objective optimization is carried out by adopting response surface methodology (RSM) for the factors affecting the maximum temperature (Tmax) and temperature difference (ΔT). Additionally, the passive flow regulation structure ensures a more uniform distribution of coolant across each cold plate. Compared with the structure without flow rate regulation, results indicate that the proposed BTMS can reduce the Tmax and ΔT by 3.50 °C and 43.15 %, respectively. Furthermore, the group efficiency is calculated to be 83.79 %, which is more beneficial to be implemented in real applications.

Suggested Citation

  • Shi, Chenwei & Xu, Jun & Guo, Zhechen & Wang, Xingzao & Mei, Xuesong, 2025. "Passive flow rate regulation and unequally spaced channel based battery thermal management system," Energy, Elsevier, vol. 320(C).
    • Handle: RePEc:eee:energy:v:320:y:2025:i:c:s0360544225009739
    DOI: 10.1016/j.energy.2025.135331
    as

    Download full text from publisher

    File URL: http://www.sciencedirect.com/science/article/pii/S0360544225009739
    Download Restriction: Full text for ScienceDirect subscribers only
    File URL: https://libkey.io/10.1016/j.energy.2025.135331?utm_source=ideas
    LibKey link: if access is restricted and if your library uses this service, LibKey will redirect you to where you can use your library subscription to access this item
    ---><---

    As the access to this document is restricted, you may want to

    for a different version of it.

    References listed on IDEAS

    as
    1. Nasiri, Mahdieh & Hadim, Hamid, 2024. "Advances in battery thermal management: Current landscape and future directions," Renewable and Sustainable Energy Reviews, Elsevier, vol. 200(C).
    2. Zhang, Yue & Song, Laifeng & Tian, Jiamin & Mei, Wenxin & Jiang, Lihua & Sun, Jinhua & Wang, Qingsong, 2024. "Modeling the propagation of internal thermal runaway in lithium-ion battery," Applied Energy, Elsevier, vol. 362(C).
    3. Zuo, Wei & Zhang, Yuntian & E, Jiaqiang & Li, Jing & Li, Qingqing & Zhang, Guangde, 2022. "Performance comparison between single S-channel and double S-channel cold plate for thermal management of a prismatic LiFePO4 battery," Renewable Energy, Elsevier, vol. 192(C), pages 46-57.
    4. Hou, Jiayang & Xu, Jun & Lin, Chuanping & Jiang, Delong & Mei, Xuesong, 2024. "State of charge estimation for lithium-ion batteries based on battery model and data-driven fusion method," Energy, Elsevier, vol. 290(C).
    5. Leitner, M. & Leubner, M.P. & Vörös, Z., 2011. "Creating kappa-like distributions from a Galton board," Physica A: Statistical Mechanics and its Applications, Elsevier, vol. 390(7), pages 1248-1257.
    6. Wang, Qian & Jiang, Bin & Li, Bo & Yan, Yuying, 2016. "A critical review of thermal management models and solutions of lithium-ion batteries for the development of pure electric vehicles," Renewable and Sustainable Energy Reviews, Elsevier, vol. 64(C), pages 106-128.
    7. Zhang, Yuntian & Zuo, Wei & E, Jiaqiang & Li, Jing & Li, Qingqing & Sun, Ke & Zhou, Kun & Zhang, Guangde, 2022. "Performance comparison between straight channel cold plate and inclined channel cold plate for thermal management of a prismatic LiFePO4 battery," Energy, Elsevier, vol. 248(C).
    8. E, Jiaqiang & Xiao, Hanxu & Tian, Sicheng & Huang, Yuxin, 2024. "A comprehensive review on thermal runaway model of a lithium-ion battery: Mechanism, thermal, mechanical, propagation, gas venting and combustion," Renewable Energy, Elsevier, vol. 229(C).
    9. Bamdezh, M.A. & Molaeimanesh, G.R., 2024. "The effect of active and passive battery thermal management systems on energy consumption, battery degradation, and carbon emissions of an electric vehicle," Energy, Elsevier, vol. 304(C).
    10. Mathieu, Romain & Briat, Olivier & Gyan, Philippe & Vinassa, Jean-Michel, 2021. "Comparison of the impact of fast charging on the cycle life of three lithium-ion cells under several parameters of charge protocol and temperatures," Applied Energy, Elsevier, vol. 283(C).
    11. Guo, Chao & Liu, Huan-ling & Guo, Qi & Shao, Xiao-dong & Zhu, Ming-liang, 2022. "Investigations on a novel cold plate achieved by topology optimization for lithium-ion batteries," Energy, Elsevier, vol. 261(PA).
    12. Ling, Ziye & Zhang, Zhengguo & Shi, Guoquan & Fang, Xiaoming & Wang, Lei & Gao, Xuenong & Fang, Yutang & Xu, Tao & Wang, Shuangfeng & Liu, Xiaohong, 2014. "Review on thermal management systems using phase change materials for electronic components, Li-ion batteries and photovoltaic modules," Renewable and Sustainable Energy Reviews, Elsevier, vol. 31(C), pages 427-438.
    Full references (including those not matched with items on IDEAS)

    Most related items

    These are the items that most often cite the same works as this one and are cited by the same works as this one.
    1. Li, Li & Ling, Lei & Xie, Yajun & Zhou, Wencai & Wang, Tianbo & Zhang, Lanchun & Bei, Shaoyi & Zheng, Keqing & Xu, Qiang, 2023. "Comparative study of thermal management systems with different cooling structures for cylindrical battery modules: Side-cooling vs. terminal-cooling," Energy, Elsevier, vol. 274(C).
    2. Kumar, Vijay & Choudhary, Akhilesh Kumar, 2024. "Prediction of the Performance and emission characteristics of diesel engine using diphenylamine Antioxidant and ceria nanoparticle additives with biodiesel based on machine learning," Energy, Elsevier, vol. 301(C).
    3. Zuo, Wei & Zhang, Yuntian & E, Jiaqiang & Huang, Yuhan & Li, Qingqing & Zhou, Kun & Zhang, Guangde, 2022. "Effects of multi-factors on performance of an improved multi-channel cold plate for thermal management of a prismatic LiFePO4 battery," Energy, Elsevier, vol. 261(PB).
    4. Liu, Huaqiang & Gao, Xiangcheng & Zhao, Jiyun & Yu, Minghao & Niu, Dong & Ji, Yulong, 2022. "Liquid-based battery thermal management system performance improvement with intersected serpentine channels," Renewable Energy, Elsevier, vol. 199(C), pages 640-652.
    5. Zhang, Chengbin & Wang, Huijuan & Huang, Yongping & Zhang, Liangliang & Chen, Yongping, 2025. "Immersion liquid cooling for electronics: Materials, systems, applications and prospects," Renewable and Sustainable Energy Reviews, Elsevier, vol. 208(C).
    6. Zuo, Wei & Li, Dexin & Li, Qingqing & Cheng, Qianju & Huang, Yuhan, 2024. "Effects of intermittent pulsating flow on the performance of multi-channel cold plate in electric vehicle lithium-ion battery pack," Energy, Elsevier, vol. 294(C).
    7. Cao, Qiang & Chen, Yuji & Wang, Zhiping & Wang, Miaomiao & Wang, Pengcheng & Ge, Lichun & Li, Peng & Zhao, Qinyu & Wang, Bo & Gan, Zhihua, 2025. "Improving the cooling efficiency of cryo-compressed hydrogen based on the temperature-distributed method in regenerative refrigerators," Energy, Elsevier, vol. 314(C).
    8. Vega-Garita, Victor & Ramirez-Elizondo, Laura & Bauer, Pavol, 2017. "Physical integration of a photovoltaic-battery system: A thermal analysis," Applied Energy, Elsevier, vol. 208(C), pages 446-455.
    9. Shan, Shuai & Li, Li & Xu, Qiang & Ling, Lei & Xie, Yajun & Wang, Hongkang & Zheng, Keqing & Zhang, Lanchun & Bei, Shaoyi, 2023. "Numerical investigation of a compact and lightweight thermal management system with axially mounted cooling tubes for cylindrical lithium-ion battery module," Energy, Elsevier, vol. 274(C).
    10. Yang, Huizhu & Li, Mingxuan & Wang, Zehui & Ma, Binjian, 2023. "A compact and lightweight hybrid liquid cooling system coupling with Z-type cold plates and PCM composite for battery thermal management," Energy, Elsevier, vol. 263(PE).
    11. Li, Dexin & Zuo, Wei & Li, Qingqing & Zhang, Guangde & Zhou, Kun & E, Jiaqiang, 2023. "Effects of pulsating flow on the performance of multi-channel cold plate for thermal management of lithium-ion battery pack," Energy, Elsevier, vol. 273(C).
    12. Wei, Li-si & Liu, Huan-ling & Tang, Chuan-geng & Tang, Xing-ping & Shao, Xiao-dong & Gongnan Xie,, 2024. "Investigation of novel type of cylindrical lithium-ion battery heat exchangers based on topology optimization," Energy, Elsevier, vol. 304(C).
    13. Zuo, Wei & Wang, Zijie & E, Jiaqiang & Li, Qingqing & Cheng, Qianju & Wu, Yinkun & Zhou, Kun, 2023. "Numerical investigations on the performance of a hydrogen-fueled micro planar combustor with tube outlet for thermophotovoltaic applications," Energy, Elsevier, vol. 263(PC).
    14. Giorgio Previati & Giampiero Mastinu & Massimiliano Gobbi, 2022. "Thermal Management of Electrified Vehicles—A Review," Energies, MDPI, vol. 15(4), pages 1-29, February.
    15. Liu, Yuanzhi & Zhang, Jie, 2019. "Design a J-type air-based battery thermal management system through surrogate-based optimization," Applied Energy, Elsevier, vol. 252(C), pages 1-1.
    16. Yan Wang & Qing Gao & Tianshi Zhang & Guohua Wang & Zhipeng Jiang & Yunxia Li, 2017. "Advances in Integrated Vehicle Thermal Management and Numerical Simulation," Energies, MDPI, vol. 10(10), pages 1-30, October.
    17. Mahmoudzadeh Andwari, Amin & Pesiridis, Apostolos & Rajoo, Srithar & Martinez-Botas, Ricardo & Esfahanian, Vahid, 2017. "A review of Battery Electric Vehicle technology and readiness levels," Renewable and Sustainable Energy Reviews, Elsevier, vol. 78(C), pages 414-430.
    18. Nasiri, Mahdieh & Hadim, Hamid, 2024. "Advances in battery thermal management: Current landscape and future directions," Renewable and Sustainable Energy Reviews, Elsevier, vol. 200(C).
    19. Lee, Changwoo, 2025. "Thermofluid topology optimization of liquid-based cooling plate for lithium-ion battery pack of EVs," Energy, Elsevier, vol. 323(C).
    20. Ćalasan, Martin & Abdel Aleem, Shady H.E. & Hasanien, Hany M. & Alaas, Zuhair M. & Ali, Ziad M., 2023. "An innovative approach for mathematical modeling and parameter estimation of PEM fuel cells based on iterative Lambert W function," Energy, Elsevier, vol. 264(C).

    More about this item

    Keywords

    ;
    ;
    ;
    ;

    Statistics

    Access and download statistics

    Corrections

    All material on this site has been provided by the respective publishers and authors. You can help correct errors and omissions. When requesting a correction, please mention this item's handle: RePEc:eee:energy:v:320:y:2025:i:c:s0360544225009739. See general information about how to correct material in RePEc.

    If you have authored this item and are not yet registered with RePEc, we encourage you to do it here. This allows to link your profile to this item. It also allows you to accept potential citations to this item that we are uncertain about.

    If CitEc recognized a bibliographic reference but did not link an item in RePEc to it, you can help with this form .

    If you know of missing items citing this one, you can help us creating those links by adding the relevant references in the same way as above, for each refering item. If you are a registered author of this item, you may also want to check the "citations" tab in your RePEc Author Service profile, as there may be some citations waiting for confirmation.

    For technical questions regarding this item, or to correct its authors, title, abstract, bibliographic or download information, contact: Catherine Liu (email available below). General contact details of provider: http://www.journals.elsevier.com/energy .

    Please note that corrections may take a couple of weeks to filter through the various RePEc services.

    IDEAS is a RePEc service. RePEc uses bibliographic data supplied by the respective publishers.