IDEAS home Printed from https://ideas.repec.org/a/eee/energy/v337y2025ics0360544225042422.html

Multi-objective topology optimization design of nanofluid cooling plate for thermal management of lithium ion battery pack

Author

Listed:
  • Wang, Jiahao
  • Liu, Bin
  • Ding, Xingqi
  • Li, Qing
  • Yu, Bo
  • Desideri, Umberto

Abstract

Designing liquid cooling plate(LCP) for lithium ion battery (LIB) packs faces challenges in optimizing and balancing multiple performance objectives, including flow resistance, heat transfer rate and temperature uniformity. To address this, an ε-constraint multi-objective topology optimization model employing nanofluid coolant is developed to design the LCP structure, which allows precise control over respective objective weights by adjusting ε-constraint factor. The study explores the impact of different coolants on LCP topology optimization structure and evaluates performance variation characteristics under various multi-objective weight factors. The developed topology optimization model effectively and accurately responds to different coolant properties and multi-objective weight factors, generating optimal structures that meet the expected requirements. Under similar performance constraints, the optimized nanofluid LCP is simpler and more efficient than pure water LCP. Across a wide Re operating range, the optimized LCPs under three different weight factors achieve superior heat transfer efficiency, temperature uniformity, and reduce pressure drop loss compared to conventional designs. Considering three performance metrics comprehensively, the ε1 = 10-ε2 = 10 LCP and ε1 = 15-ε2 = 8 LCP exhibit the best overall performance, while the rectangular fin LCP performs the worst. At Re = 600, respectively compared to the cylinder fin LCP and rectangular fin LCP, the heat transfer efficiency of the ε1 = 15-ε2 = 8 LCP increases by 2.6 times and 3.7 times; the maximum temperature difference under the ε1 = 10-ε2 = 10 LCP is reduced by 1.1K and 2.3K; the pressure drop in the ε1 = 5-ε2 = 8 LCP is reduced by 50.3 % and 58.3 %. The optimized LCP structures utilize locally drag-reducing structures (spindle-shaped leading edge, streamlined-wavy wall, elliptical profile trailing edge) and the global layout features (global irregular discontinuity) to suppress the generation and development of low-speed stagnation vortex, wake formations, and boundary layer thickening, which synergistically enhances heat transfer, temperature uniformity, and pressure drop characteristics.

Suggested Citation

  • Wang, Jiahao & Liu, Bin & Ding, Xingqi & Li, Qing & Yu, Bo & Desideri, Umberto, 2025. "Multi-objective topology optimization design of nanofluid cooling plate for thermal management of lithium ion battery pack," Energy, Elsevier, vol. 337(C).
    • Handle: RePEc:eee:energy:v:337:y:2025:i:c:s0360544225042422
    DOI: 10.1016/j.energy.2025.138600
    as

    Download full text from publisher

    File URL: http://www.sciencedirect.com/science/article/pii/S0360544225042422
    Download Restriction: Full text for ScienceDirect subscribers only
    File URL: https://libkey.io/10.1016/j.energy.2025.138600?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. Jouhara, Hussam & Khordehgah, Navid & Serey, Nicolas & Almahmoud, Sulaiman & Lester, Stephen P. & Machen, Daniel & Wrobel, Luiz, 2019. "Applications and thermal management of rechargeable batteries for industrial applications," Energy, Elsevier, vol. 170(C), pages 849-861.
    2. Xu, X.M. & He, R., 2014. "Review on the heat dissipation performance of battery pack with different structures and operation conditions," Renewable and Sustainable Energy Reviews, Elsevier, vol. 29(C), pages 301-315.
    3. Srimuang, W. & Amatachaya, P., 2012. "A review of the applications of heat pipe heat exchangers for heat recovery," Renewable and Sustainable Energy Reviews, Elsevier, vol. 16(6), pages 4303-4315.
    4. Tan, Kang Miao & Yong, Jia Ying & Ramachandaramurthy, Vigna K. & Mansor, Muhamad & Teh, Jiashen & Guerrero, Josep M., 2023. "Factors influencing global transportation electrification: Comparative analysis of electric and internal combustion engine vehicles," Renewable and Sustainable Energy Reviews, Elsevier, vol. 184(C).
    5. 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).
    6. Xia, Yang & Chen, Li & Luo, Jiwang & Tao, Wenquan, 2023. "Numerical investigation of microchannel heat sinks with different inlets and outlets based on topology optimization," Applied Energy, Elsevier, vol. 330(PA).
    7. Thomas Imre Cyrille Buidin & Florin Mariasiu, 2021. "Battery Thermal Management Systems: Current Status and Design Approach of Cooling Technologies," Energies, MDPI, vol. 14(16), pages 1-32, August.
    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. 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).
    2. 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).
    3. Jiang, Z.Y. & Qu, Z.G., 2019. "Lithium–ion battery thermal management using heat pipe and phase change material during discharge–charge cycle: A comprehensive numerical study," Applied Energy, Elsevier, vol. 242(C), pages 378-392.
    4. Raja Mazuir Raja Ahsan Shah & Mansour Al Qubeissi & Hazem Youssef & Hakan Serhad Soyhan, 2023. "Battery Thermal Management: An Application to Petrol Hybrid Electric Vehicles," Sustainability, MDPI, vol. 15(7), pages 1-19, March.
    5. Zhang, Zihui & Han, Dong & Xiong, Jiaming & Lin, Zhiwei & Tang, Peihao & Wang, Hejing & He, Weifeng, 2025. "Evaluation of a novel indirect liquid-cooling system for energy storage batteries via mechanical vapor recompression and falling film evaporation," Energy, Elsevier, vol. 317(C).
    6. Ma, Xiaojing & Xu, Jinliang & Xie, Jian, 2021. "In-situ phase separation to improve phase change heat transfer performance," Energy, Elsevier, vol. 230(C).
    7. Sun, Fangtian & Fu, Lin & Sun, Jian & Zhang, Shigang, 2014. "A new ejector heat exchanger based on an ejector heat pump and a water-to-water heat exchanger," Applied Energy, Elsevier, vol. 121(C), pages 245-251.
    8. Cheng, Jia-Hao & Cao, Xiang & Shao, Liang-Liang & Zhang, Chun-Lu, 2023. "Performance evaluation of a novel heat pump system for drying with EVI-compressor driven precooling and reheating," Energy, Elsevier, vol. 278(PB).
    9. Al-Zareer, Maan & Dincer, Ibrahim & Rosen, Marc A., 2019. "Comparative assessment of new liquid-to-vapor type battery cooling systems," Energy, Elsevier, vol. 188(C).
    10. Jannesar Niri, Anahita & Poelzer, Gregory A. & Zhang, Steven E. & Rosenkranz, Jan & Pettersson, Maria & Ghorbani, Yousef, 2024. "Sustainability challenges throughout the electric vehicle battery value chain," Renewable and Sustainable Energy Reviews, Elsevier, vol. 191(C).
    11. Tang, Heng & Tang, Yong & Wan, Zhenping & Li, Jie & Yuan, Wei & Lu, Longsheng & Li, Yong & Tang, Kairui, 2018. "Review of applications and developments of ultra-thin micro heat pipes for electronic cooling," Applied Energy, Elsevier, vol. 223(C), pages 383-400.
    12. Bingxiang Sun & Xianjie Qi & Donglin Song & Haijun Ruan, 2023. "Review of Low-Temperature Performance, Modeling and Heating for Lithium-Ion Batteries," Energies, MDPI, vol. 16(20), pages 1-37, October.
    13. Guo, Chao & Chen, Li & Tao, Wenquan, 2025. "Topology optimization of the gas distribution zone uniformity in proton exchange membrane fuel cells," Energy, Elsevier, vol. 340(C).
    14. Donmez, Muhammed & Tekin, Merve & Karamangil, Mehmet Ihsan, 2025. "Comparative analysis of optimum thermal management systems for battery modules comprising 32700 and 18650 LFP cells at equivalent power capacity level," Energy, Elsevier, vol. 339(C).
    15. Wang, Xueli & Zhang, Pengju & Du, Yan & Liu, Lang & Fang, Jiabin & Ji, Changfa & Wang, Mei & Zhang, Bo & Huan, Chao, 2024. "Numerical investigation on the heat storage/heat release performance enhancement of phase change cemented paste backfill body with using casing-type heat pipe heat exchangers," Renewable Energy, Elsevier, vol. 225(C).
    16. 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).
    17. 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).
    18. Orhan Yalçınkaya & Ufuk Durmaz & Ahmet Ümit Tepe & Ali Cemal Benim & Ünal Uysal, 2024. "Heat and Flow Characteristics of Aerofoil-Shaped Fins on a Curved Target Surface in a Confined Channel for an Impinging Jet Array," Energies, MDPI, vol. 17(5), pages 1-21, March.
    19. 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).
    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:337:y:2025:i:c:s0360544225042422. 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.