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<p>This numerical study examines the impact of flow configuration for an improved minichannel cold plate with a fragmented design. With simple modifications to the existing design, the improved design offers better heat augmentation capability along with reduced pressure drop. The initial analysis focused on the flow configurations of traditional serpentine minichannel design cold plates (D1–D6) integrated on a single battery. Then, an improved fragmented channel design with different flow configurations (D2FF, D3FF, and D4FF) is proposed to enhance the cold plate's cooling efficiency. To assess the temperature distribution at the module level, a 1P3S (P–parallel and S–series) battery module is integrated with the improved design and investigated under different operating conditions. There is a 68.14% reduction in pressure drop in the fragmented design compared to the traditional design. The maximum temperature rise at the cell level is 5.062, 4.98, and 5.06&#xa0;K for the D2FF, D3FF, and D4FF designs, respectively. A 37.5% reduction in maximum temperature rise is observed for the fragmented flow design. Among the fragmented flow designs, the D3FF flow configuration shows better temperature uniformity with a temperature difference of 1.545&#xa0;K, 24.45% less than the traditional circuitous design D3. Thus, while evaluating the heat transfer and hydrodynamic performance of minichannel cold plates integrated with the battery, it is imperative to carefully consider the flow configuration&#xa0;as it plays a crucial role in determining the temperature uniformity throughout the battery. Thermal abuse in the form of external shorting with harsh heat generation characteristics is also simulated to evaluate the performance of the cooling system under extreme conditions, and the use of the D3FF design cold plates helped to avert the rise in temperatures within acceptable ranges.</p>

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Indirect liquid-cooled lithium-ion battery module with improved circuitous minichannel cold plate design: a numerical study involving the effect of different flow configurations

  • 期刊论文

  • 发表日期：

    2025年8月25日

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  • Jyoti Ranjan Mohapatra,
  • Manoj Kumar Moharana,
  • Satyam Panchal

摘要

This numerical study examines the impact of flow configuration for an improved minichannel cold plate with a fragmented design. With simple modifications to the existing design, the improved design offers better heat augmentation capability along with reduced pressure drop. The initial analysis focused on the flow configurations of traditional serpentine minichannel design cold plates (D1–D6) integrated on a single battery. Then, an improved fragmented channel design with different flow configurations (D2FF, D3FF, and D4FF) is proposed to enhance the cold plate's cooling efficiency. To assess the temperature distribution at the module level, a 1P3S (P–parallel and S–series) battery module is integrated with the improved design and investigated under different operating conditions. There is a 68.14% reduction in pressure drop in the fragmented design compared to the traditional design. The maximum temperature rise at the cell level is 5.062, 4.98, and 5.06 K for the D2FF, D3FF, and D4FF designs, respectively. A 37.5% reduction in maximum temperature rise is observed for the fragmented flow design. Among the fragmented flow designs, the D3FF flow configuration shows better temperature uniformity with a temperature difference of 1.545 K, 24.45% less than the traditional circuitous design D3. Thus, while evaluating the heat transfer and hydrodynamic performance of minichannel cold plates integrated with the battery, it is imperative to carefully consider the flow configuration as it plays a crucial role in determining the temperature uniformity throughout the battery. Thermal abuse in the form of external shorting with harsh heat generation characteristics is also simulated to evaluate the performance of the cooling system under extreme conditions, and the use of the D3FF design cold plates helped to avert the rise in temperatures within acceptable ranges.