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Thermofluid topology optimization of liquid-based cooling plate for lithium-ion battery pack of EVs

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  • Lee, Changwoo

Abstract

This study proposes a new thermofluid topology optimization (TO) framework to design an optimal liquid-based cooling plate for Li-ion battery packs. To resolve the numerical issues of the previous thermofluid TO formulation (i.e., intermediate densities and locally high temperatures), this study proposes new penalization schemes, i.e., black-and-white and temperature penalty schemes. In contrast to the previous scheme, the proposed schemes allow optimized materials to be clearly distinguished into solid or fluid phases. Additionally, they enable the suppression of locally high temperatures to achieve a uniform temperature distribution. To demonstrate the manufacturability of the prototype, an optimized cooling plate is manufactured. Experimental results validate the effectiveness of the proposed framework. The proposed optimization framework can be utilized to determine the optimal liquid-based cooling plate for EVs to achieve a low-pressure drop and a uniform temperature distribution.

Suggested Citation

  • Lee, Changwoo, 2025. "Thermofluid topology optimization of liquid-based cooling plate for lithium-ion battery pack of EVs," Energy, Elsevier, vol. 323(C).
    • Handle: RePEc:eee:energy:v:323:y:2025:i:c:s0360544225013544
    DOI: 10.1016/j.energy.2025.135712
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    References listed on IDEAS

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    1. Zhang, Xinghui & Li, Zhao & Luo, Lingai & Fan, Yilin & Du, Zhengyu, 2022. "A review on thermal management of lithium-ion batteries for electric vehicles," Energy, Elsevier, vol. 238(PA).
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    4. 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).
    5. Waelveerakup, Sorravit & Thanomthong, Kasidith & Tantivimonkajorn, Punnapop & Wanittansirichok, Vichapol & Mongkholphan, Kanich & Sakamatapan, Kittipong & Promoppatum, Patcharapit & Wongwises, Somchai, 2024. "Comprehensive examination of topologically optimized thermo-fluid heat sinks," Energy, Elsevier, vol. 298(C).
    6. 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).
    7. Jaguemont, J. & Boulon, L. & Dubé, Y., 2016. "A comprehensive review of lithium-ion batteries used in hybrid and electric vehicles at cold temperatures," Applied Energy, Elsevier, vol. 164(C), pages 99-114.
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