Optimizing Indirect Liquid Cooling System for Thermal Management of Electric Vehicle Battery: A CFD Study Using Cold Plate

Abstract

Traditional fuels and internal combustion engines are major sources of CO2 emissions and environmental pollution. Electric vehicles (EVs) are touted as green energy solutions for a cleaner future. EVs utilize lithium-ion batteries, but face challenges such as poor performance in extreme temperatures, limited electrode lifespan, and safety risks from battery thermal runaway. Effective Battery Thermal Management Systems (BTMS) are crucial for EV longevity. The study emphasizes the crucial role of coolant selection, structural design, and channel configuration in optimizing indirect liquid cooling systems for EV batteries. Conducted through comprehensive CFD analysis using a cold plate, it specifically examined three key parameters: the impact of different coolants, various cold plate structures, and the number of channels. Findings indicated that a 50% ethylene glycol-water (EGW) solution outperformed pure water in performance metrics. Additionally, streamlined channel cold plates demonstrated superior temperature uniformity and reduced pressure drops, establishing them as the most efficient design option. This streamlined design facilitated enhanced heat transfer while minimizing pressure losses, confirming its suitability for EV battery cooling applications.