Optimization and thermal performance analysis of direct cooling plates with multi-splitting-merging channels for electric-vehicle battery thermal management

IF 4.9 2区工程技术 Q1 ENGINEERING, MECHANICAL

International Journal of Thermal Sciences Pub Date : 2025-03-30 DOI:10.1016/j.ijthermalsci.2025.109900

Yubo Lian , Heping Ling , Gan Song , Keyu Gong , Chao Fan , Feng Wang , Bin He

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引用次数: 0

Abstract

The multi-channel battery thermal management system (BTMS) based on refrigerant direct cooling has the characteristics of high cooling efficiency and excellent temperature uniformity. It is expected to alleviate the problems of a large amount of heat generation and excessively high local temperature of lithium-ion batteries in electric vehicles during the rapid charge and discharge process. In practical applications, the cooling effect of the direct cooling method is closely related to the dimension and distribution of the mini-channels on the direct cooling plate (DCP). However, the large number of mini-channels and their intricate dimension and distribution pose challenges to both experimental research and numerical modeling. Therefore, in order to analyze the heat transfer performance of the large-format and multi-splitting-merging DCP, this study firstly integrated the correlation algorithm and the tensor operator to establish a novel model of two-phase refrigerant heat transfer. After comparison with the experimental results, this study analyzed the causes of local overheating of a mass-produced DCP. To eliminate the overheated zone, this study proposed an optimization criteria on the dimension and distribution of the mini-channels of DCP. After optimization, the maximum temperature of the DCP is reduced from 42 °C to 31 °C, the maximum temperature difference is less than 5 °C, and the pressure drop of the DCP is reduced from 95 kPa to 72 kPa. The optimized DCP could increase the charge/discharge cycle life of lithium-ion batteries by 30.7 %, and reduce the energy consumption of the compressor by 6.4 % in comparison with the mass-produced DCP. These results can potentially provide a promising thermal management solution for lithium-ion batteries.

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电动汽车电池热管理多分合通道直接冷却板优化及热性能分析

基于制冷剂直接冷却的多通道电池热管理系统（BTMS）具有冷却效率高、温度均匀性好的特点。它有望缓解电动汽车锂离子电池在快速充放电过程中发热量大、局部温度过高等问题。在实际应用中，直接冷却法的冷却效果与直接冷却板（DCP）上微型通道的尺寸和分布密切相关。然而，大量的微型通道及其错综复杂的尺寸和分布给实验研究和数值建模带来了挑战。因此，为了分析大尺寸多分流合并直接冷却板的传热性能，本研究首先综合了相关算法和张量算子，建立了一种新型的两相制冷剂传热模型。在与实验结果进行对比后，本研究分析了量产 DCP 局部过热的原因。为了消除过热区，本研究提出了 DCP 微型通道尺寸和分布的优化标准。优化后，DCP 的最高温度从 42 ℃ 降至 31 ℃，最大温差小于 5 ℃，压降从 95 kPa 降至 72 kPa。与大规模生产的 DCP 相比，优化后的 DCP 可将锂离子电池的充放电循环寿命提高 30.7%，并将压缩机的能耗降低 6.4%。这些结果有可能为锂离子电池提供一种前景广阔的热管理解决方案。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

International Journal of Thermal Sciences 工程技术-工程：机械

CiteScore

8.10

自引率

11.10%

发文量

531

审稿时长

55 days

期刊介绍： The International Journal of Thermal Sciences is a journal devoted to the publication of fundamental studies on the physics of transfer processes in general, with an emphasis on thermal aspects and also applied research on various processes, energy systems and the environment. Articles are published in English and French, and are subject to peer review. The fundamental subjects considered within the scope of the journal are: * Heat and relevant mass transfer at all scales (nano, micro and macro) and in all types of material (heterogeneous, composites, biological,...) and fluid flow * Forced, natural or mixed convection in reactive or non-reactive media * Single or multi–phase fluid flow with or without phase change * Near–and far–field radiative heat transfer * Combined modes of heat transfer in complex systems (for example, plasmas, biological, geological,...) * Multiscale modelling The applied research topics include: * Heat exchangers, heat pipes, cooling processes * Transport phenomena taking place in industrial processes (chemical, food and agricultural, metallurgical, space and aeronautical, automobile industries) * Nano–and micro–technology for energy, space, biosystems and devices * Heat transport analysis in advanced systems * Impact of energy–related processes on environment, and emerging energy systems The study of thermophysical properties of materials and fluids, thermal measurement techniques, inverse methods, and the developments of experimental methods are within the scope of the International Journal of Thermal Sciences which also covers the modelling, and numerical methods applied to thermal transfer.