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<p>The thermal management of lithium-ion battery systems is essential for ensuring their safety, performance, and longevity, especially during high-power operations. This study presents an innovative liquid-cooled microchannel-based thermal management system for a cylindrical 21,700-type lithium-ion battery pack consisting of 10 cells. The research investigates the impact of varying Reynolds numbers on critical performance parameters, including maximum battery pack temperature, thermal uniformity, convective heat transfer coefficient, coolant outlet temperature, and pressure drop. Performance evaluation utilized microchannel geometries with square, rectangular, and circular cross-sections. Furthermore, the study assesses the effects of cross-flow configurations on the efficiency of the thermal management system. A three-dimensional simulation model was employed to analyze the thermo-hydraulic behavior of the proposed system across a range of Reynolds numbers from 400 to 700. Circular microchannels demonstrated superior cooling performance among the analyzed geometries, enhancing the thermo-hydraulic performance ratio by 2% and 4% compared to square and rectangular geometries, respectively, at a Reynolds number of 700. The maximum battery pack temperature and thermal gradient achieved with the circular geometry were 32.65&#xa0;°C and 1.89&#xa0;°C, respectively, reflecting improvements of 8% and 14% over the square and rectangular geometries. The introduction of a cross-flow configuration further reduced the maximum battery pack temperature by 10%, decreasing it from 35.75&#xa0;°C at a Reynolds number of 400–30.2&#xa0;°C at a Reynolds number of 700, while also enhancing thermal uniformity with a 9% improvement over a parallel-flow arrangement.</p>

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Numerical study on impact of channel geometry and flow configurations on thermal and hydraulic performance of microchannel liquid-cooled battery thermal management system

  • 期刊论文

  • 发表日期：

    2025年8月8日

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  • Akash S. Bidwaik,
  • Siddappa S. Bhusnoor,
  • Shailesh R. Nikam

摘要

The thermal management of lithium-ion battery systems is essential for ensuring their safety, performance, and longevity, especially during high-power operations. This study presents an innovative liquid-cooled microchannel-based thermal management system for a cylindrical 21,700-type lithium-ion battery pack consisting of 10 cells. The research investigates the impact of varying Reynolds numbers on critical performance parameters, including maximum battery pack temperature, thermal uniformity, convective heat transfer coefficient, coolant outlet temperature, and pressure drop. Performance evaluation utilized microchannel geometries with square, rectangular, and circular cross-sections. Furthermore, the study assesses the effects of cross-flow configurations on the efficiency of the thermal management system. A three-dimensional simulation model was employed to analyze the thermo-hydraulic behavior of the proposed system across a range of Reynolds numbers from 400 to 700. Circular microchannels demonstrated superior cooling performance among the analyzed geometries, enhancing the thermo-hydraulic performance ratio by 2% and 4% compared to square and rectangular geometries, respectively, at a Reynolds number of 700. The maximum battery pack temperature and thermal gradient achieved with the circular geometry were 32.65 °C and 1.89 °C, respectively, reflecting improvements of 8% and 14% over the square and rectangular geometries. The introduction of a cross-flow configuration further reduced the maximum battery pack temperature by 10%, decreasing it from 35.75 °C at a Reynolds number of 400–30.2 °C at a Reynolds number of 700, while also enhancing thermal uniformity with a 9% improvement over a parallel-flow arrangement.