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Lithium-ion batteries play a critical role in advancing smart mobility and driving the energy transition, with efficient thermal management being essential to ensure their safety, performance, and longevity. This study evaluates the thermal efficiency of a novel U-shaped aluminum cold plate BTMS integrated with a pouch lithium-ion cell, using water as the cooling agent. The system’s performance was analyzed through Computational Fluid Dynamics (CFD) simulations, validated against experimental data. Simulations conducted at discharge rates of 1C, 2C, 3C, and 4C demonstrated that an inlet mass flow rate of 5 × 10−4 kg/s effectively maintained Tb,max at 25.29 °C, 26.13 °C, 27.49 °C, and 29.28 °C, respectively, while ensuring ΔTb,max remained at 0.270 °C, 1.034 °C, 2.287 °C, and 3.941 °C. To enhance safety under aggressive driving conditions by minimizing ΔTb,max, the inlet mass flow rate was increased incrementally to 1 × 10−3, 1.5 × 10−3, 2 × 10−3, 2.5 × 10−3, and 3 × 10−3 kg/s. Key performance metrics such as Tb,max, ΔTb,max, uniformity index, Nusselt number, friction coefficient, and cooling efficiency factor were optimized, identifying an inlet mass flow rate of 2 × 10−3 kg/s as the optimal value for the proposed BTMS.

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Optimization of a U-Shaped Cold Plate BTMS for Lithium-Ion Batteries Using CFD: Thermal Regulation Under Various Discharge Rates and Applications for Smart Mobility

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  • 发表日期：

    2026年

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  • Nassreddine Hmidi,
  • Hicham Kaddouri,
  • Ahmed Alami Merrouni,
  • Abdel-illah Amrani,
  • Elmiloud Chaabelasri

摘要

Lithium-ion batteries play a critical role in advancing smart mobility and driving the energy transition, with efficient thermal management being essential to ensure their safety, performance, and longevity. This study evaluates the thermal efficiency of a novel U-shaped aluminum cold plate BTMS integrated with a pouch lithium-ion cell, using water as the cooling agent. The system’s performance was analyzed through Computational Fluid Dynamics (CFD) simulations, validated against experimental data. Simulations conducted at discharge rates of 1C, 2C, 3C, and 4C demonstrated that an inlet mass flow rate of 5 × 10−4 kg/s effectively maintained Tb,max at 25.29 °C, 26.13 °C, 27.49 °C, and 29.28 °C, respectively, while ensuring ΔTb,max remained at 0.270 °C, 1.034 °C, 2.287 °C, and 3.941 °C. To enhance safety under aggressive driving conditions by minimizing ΔTb,max, the inlet mass flow rate was increased incrementally to 1 × 10−3, 1.5 × 10−3, 2 × 10−3, 2.5 × 10−3, and 3 × 10−3 kg/s. Key performance metrics such as Tb,max, ΔTb,max, uniformity index, Nusselt number, friction coefficient, and cooling efficiency factor were optimized, identifying an inlet mass flow rate of 2 × 10−3 kg/s as the optimal value for the proposed BTMS.