Improving Electric Vehicle Air-Cooled Cylindrical Battery Temperature Control Systems: A Computational Fluid Dynamics (CFD) Study of an Innovative Uniform Flow Distribution Plate

Temperature significantly affects the operation of lithium-ion batteries in electric vehicles (EVs). A battery temperature management system (BTMS) is necessary for battery safety and extended lifespan. This study proposes an innovative flow circulation technique to achieve uniform airflow distribution throughout the 26 650 cylindrical cells arranged in a 5P5S configuration. The 3D models of nine aluminum perforated plates with varying topologies have been developed to identify a more effective cooling method for rectangular battery packs. The CFD simulations examine the effects of air velocities, air inlet temperatures, C rate, and cell spacing (L) on the nine-plate structure. Optimal cooling is achieved with 2 mm cell spacing, evenly dispersing airflow and enhancing heat dissipation. An investigation has been conducted for various C rates. The best thermal performance is obtained at air speeds of 0.8 m/s for 0.5 C, 5 m/s for 1C, and 30 m/s for 2C. The outcome shows that altering the flow distribution layout is a practical way to improve the BP's cooling capacity.