IDEAS home Printed from https://ideas.repec.org/a/eee/energy/v336y2025ics0360544225041003.html

Numerical research on baffle-enhanced liquid immersion cooling for thermal regulation in 280 Ah LiFePO4 batteries

Author

Listed:
  • Peng, Ao
  • Peng, Fei
  • Chen, Yuehao
  • Peng, Qi
  • Sun, Xiaoqin
  • Li, Jie

Abstract

The growing demand for energy storage systems, coupled with the increasing utilization of LiFePO4 batteries, has highlighted the need for effective thermal management solutions. As a thermal regulation strategy, liquid immersion cooling offers a promising approach for managing battery module temperatures. In this study, a flow-based liquid immersion cooling system with the addition of baffles for battery thermal management (BTMS) is proposed. Three different types of baffle configurations are introduced, and the effects of varying inlet velocities and temperatures are investigated. The flow and temperature fields of the three BTMS configurations are analyzed to evaluate their thermal performance. An optimized combination is proposed using an orthogonal array testing, incorporating coolant temperature, flow rate, and baffle configurations. The simulation results reveal that the optimized configuration leads to a 31.57 % reduction in the maximum temperature and a 17.8 % decrease in the maximum temperature difference within the battery module. This study provides valuable insights into temperature regulation strategies for high-energy battery systems.

Suggested Citation

  • Peng, Ao & Peng, Fei & Chen, Yuehao & Peng, Qi & Sun, Xiaoqin & Li, Jie, 2025. "Numerical research on baffle-enhanced liquid immersion cooling for thermal regulation in 280 Ah LiFePO4 batteries," Energy, Elsevier, vol. 336(C).
    • Handle: RePEc:eee:energy:v:336:y:2025:i:c:s0360544225041003
    DOI: 10.1016/j.energy.2025.138458
    as

    Download full text from publisher

    File URL: http://www.sciencedirect.com/science/article/pii/S0360544225041003
    Download Restriction: Full text for ScienceDirect subscribers only
    File URL: https://libkey.io/10.1016/j.energy.2025.138458?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. Zhiyu Zhang & Rongrong Zhai & Xinwei Wang & Yongping Yang, 2020. "Sensitivity Analysis and Optimization of Operating Parameters of an Oxyfuel Combustion Power Generation System Based on Single-Factor and Orthogonal Design Methods," Energies, MDPI, vol. 13(4), pages 1-22, February.
    2. Zhang, Jiangyun & Shao, Dan & Jiang, Liqin & Zhang, Guoqing & Wu, Hongwei & Day, Rodney & Jiang, Wenzhao, 2022. "Advanced thermal management system driven by phase change materials for power lithium-ion batteries: A review," Renewable and Sustainable Energy Reviews, Elsevier, vol. 159(C).
    3. Sun, Wei & Li, Peng & Cheng, Wenmin & Li, Chongchong & Qi, Xiaolong & Shen, Han & Shao, Xiaodong, 2025. "Novel hybrid thermal management system for cylindrical lithium-ion battery based on CPCM and topology-optimized liquid cooling," Energy, Elsevier, vol. 329(C).
    4. Prahit Dubey & Gautam Pulugundla & A. K. Srouji, 2021. "Direct Comparison of Immersion and Cold-Plate Based Cooling for Automotive Li-Ion Battery Modules," Energies, MDPI, vol. 14(5), pages 1-19, February.
    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. Wahab, Abdul & Najmi, Aezid-Ul-Hassan & Senobar, Hossein & Amjady, Nima & Kemper, Hans & Khayyam, Hamid, 2025. "Immersion cooling innovations and critical hurdles in Li-ion battery cooling for future electric vehicles," Renewable and Sustainable Energy Reviews, Elsevier, vol. 211(C).
    2. Liu, Jiahao & Fan, Yining & Wang, Jinhui & Tao, Changfa & Chen, Mingyi, 2022. "A model-scale experimental and theoretical study on a mineral oil-immersed battery cooling system," Renewable Energy, Elsevier, vol. 201(P1), pages 712-723.
    3. Wang, Qirui & Wang, Xiang & Gu, Xiaobin & Zhou, Yongquan & Nian, Hongen, 2025. "Thermal absorption enhancement of a flexible hydrated salts phase change film for efficient thermal dissipation of electronic devices," Energy, Elsevier, vol. 335(C).
    4. 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).
    5. Wu, Chunxia & Sun, Yalong & Tang, Heng & Zhang, Shiwei & Yuan, Wei & Zhu, Likuan & Tang, Yong, 2024. "A review on the liquid cooling thermal management system of lithium-ion batteries," Applied Energy, Elsevier, vol. 375(C).
    6. Liu, Jiahao & Tao, Liyanyu & Yang, Qinyuan & Wang, Jinhui, 2026. "Recent advances in immersion cooling for thermal management of lithium-ion batteries," Renewable and Sustainable Energy Reviews, Elsevier, vol. 226(PE).
    7. Zhao, Jingyuan & Wang, Zhenghong & Wu, Yuyan & Burke, Andrew F., 2025. "Predictive pretrained transformer (PPT) for real-time battery health diagnostics," Applied Energy, Elsevier, vol. 377(PD).
    8. Shi, Zhiwei & Tian, Xinghua & Peng, Qingguo & Huang, Zhixin & Teng, Peng & Yin, Ruixue, 2025. "Effects analysis of hydrogen production from methanol reforming of dual-U reactor for fuel-cell hybrid electric vehicles," Energy, Elsevier, vol. 318(C).
    9. Gharehghani, Ayat & Rabiei, Moeed & Mehranfar, Sadegh & Saeedipour, Soheil & Mahmoudzadeh Andwari, Amin & García, Antonio & Reche, Carlos Mico, 2024. "Progress in battery thermal management systems technologies for electric vehicles," Renewable and Sustainable Energy Reviews, Elsevier, vol. 202(C).
    10. Chen, Mingyi & Yu, Yue & Ouyang, Dongxu & Weng, Jingwen & Zhao, Luyao & Wang, Jian & Chen, Yin, 2024. "Research progress of enhancing battery safety with phase change materials," Renewable and Sustainable Energy Reviews, Elsevier, vol. 189(PA).
    11. 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).
    12. Hasan, Husam Abdulrasool & Togun, Hussein & Abed, Azher M & Biswas, Nirmalendu & Mohammed, Hayder I., 2023. "Thermal performance assessment for an array of cylindrical Lithium-Ion battery cells using an Air-Cooling system," Applied Energy, Elsevier, vol. 346(C).
    13. He, Junjie & Chu, Wenxiao & Wang, Qiuwang, 2025. "Applications of low melting point alloy for electronic thermal management: A review," Renewable and Sustainable Energy Reviews, Elsevier, vol. 210(C).
    14. Sang Kwon Yi & Chie Hoon Song, 2025. "A Dual-Level Prediction Approach for Uncovering Technology Convergence Opportunities: The Case of Electric Vehicles," Sustainability, MDPI, vol. 17(8), pages 1-23, April.
    15. Zhang, Hong & Zhao, Yuxuan & Tian, Yu & Zhang, Yifan & Tao, Zhenyi & Xu, Shiqi, 2025. "Multi-level optimization of low-temperature heating methods for large-capacity lithium-ion batteries based on temperature uniformity," Energy, Elsevier, vol. 330(C).
    16. Suresh, C. & Awasthi, Abhishek & Kumar, Binit & Im, Seong-kyun & Jeon, Yongseok, 2025. "Advances in battery thermal management for electric vehicles: A comprehensive review of hybrid PCM-metal foam and immersion cooling technologies," Renewable and Sustainable Energy Reviews, Elsevier, vol. 208(C).
    17. Brian Azzopardi & Abdul Hapid & Sunarto Kaleg & Sudirja & Djulia Onggo & Alexander C. Budiman, 2023. "Recent Advances in Battery Pack Polymer Composites," Energies, MDPI, vol. 16(17), pages 1-23, August.
    18. He, Junjie & Chu, Wenxiao & Wang, Qiuwang, 2024. "Interfacial heat transfer and melt-front evolution at a Fractal Cantor structured interface under various PCM melting conditions," Energy, Elsevier, vol. 294(C).
    19. Zhu, Zehua & Zhang, Zhendong & Kuang, Zhiwei & Qin, Wenjin & Yin, Congbo, 2025. "Multi-objective optimization of immersion cooling system for large-capacity lithium-ion battery with collaborative thermal management structures," Energy, Elsevier, vol. 328(C).
    20. Krzysztof Górecki & Krzysztof Posobkiewicz, 2022. "Cooling Systems of Power Semiconductor Devices—A Review," Energies, MDPI, vol. 15(13), pages 1-29, June.

    More about this item

    Keywords

    ;
    ;
    ;
    ;
    ;

    JEL classification:

    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:336:y:2025:i:c:s0360544225041003. 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.