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Multi-objective topology optimization of liquid-cooled plate structures for enhanced thermal management in power batteries

Author

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  • Chaoyu, Jiang
  • Xing, Wu
  • Tao, Liu
  • Henjie, Hu
  • Jixi, Yang

Abstract

With the rapid development of new energy vehicles, the thermal management of power batteries is crucial for improving performance and ensuring safety. Liquid-cooled plates, an efficient cooling method, can significantly enhance heat transfer efficiency and temperature consistency through optimized design. This study proposes a multi-objective optimization strategy based on a topology optimization approach, which develops 2D and 3D electro-thermal-fluid coupling models. These models analyze the influence of weighting factors, flow rates, and fluid volume fractions on the performance of liquid-cooled plates. The results reveal that at an average fluid volume fraction of 0.5, the optimized liquid-cooled plate (TOP structure) results in a pressure drop of merely 17.595 Pa, which is approximately 40 % lower than the 29.3 Pa pressure drop of a conventional linear cooling plate (LCP structure). Furthermore, the TOP structure maintains a maximum temperature below 302.5 K, indicating a decrease of approximately 1.7 K compared to the maximum temperature of 304.2K of the LCP structure. Moreover, the TOP structure exhibits higher thermal performance across different inlet velocities, with its maximum and average temperatures stabilizing at an inlet velocity of 0.04 m/s. The results indicate that the topology-optimized liquid-cooled plate significantly exceeds conventional thermal performance and fluid characteristics designs, offering a highly efficient and reliable solution for the thermal management power battery.

Suggested Citation

  • Chaoyu, Jiang & Xing, Wu & Tao, Liu & Henjie, Hu & Jixi, Yang, 2025. "Multi-objective topology optimization of liquid-cooled plate structures for enhanced thermal management in power batteries," Energy, Elsevier, vol. 341(C).
    • Handle: RePEc:eee:energy:v:341:y:2025:i:c:s0360544225050637
    DOI: 10.1016/j.energy.2025.139421
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    References listed on IDEAS

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    1. 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).
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    5. 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).
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