Effect of flow pattern and channel cross section on thermal management of cylindrical batteries with solid blocks containing liquid channels

The escalating prevalence of electric vehicles in industrial and military applications is driven by factors such as reduced environmental impact through lower emissions (air pollution and noise) and the inherent advantages of high power density and low maintenance requirements. Lithium-ion batteries, as the primary energy source for these vehicles, are critically susceptible to elevated operating temperatures, which significantly compromises their performance and can lead to premature failure. Effective thermal management systems are thus imperative to ensure optimal battery operation. This study investigates a thermal management strategy utilizing solid blocks incorporating liquid coolant channels. The research comprehensively examines the influence of channel cross-sectional geometry (rectangular and square) and flow patterns (parallel and counter-flow) on thermal performance and pressure drop across a range of discharge rates. Key performance indicators include the maximum temperature within the battery module and the temperature differential across the module. The findings demonstrate that counter-flow configurations consistently exhibit lower peak temperatures compared to parallel-flow arrangements. Notably, the rectangular channel with counter-flow achieved the lowest maximum temperature of 38.47 °C at the highest discharge rate (3C) investigated. Furthermore, counter-flow systems exhibited significantly lower temperature differentials within the battery module. The channel with a square section can record the lowest pressure drop, which is about 1.8 pa less pressure drop in the counter flow pattern than the parallel one and it is equal to 66.25 pa. For instance, at a 3C discharge rate, the temperature difference across the module in the rectangular channel was 7.1 °C for parallel flow and 2.12 °C for counter-flow, respectively. The analysis also revealed that square channels with counter-flow configurations generally exhibited lower pressure drops. In summary, rectangular channels achieved the highest hydrothermal performance (η) in both flow patterns, with values of 1.23 for parallel flow and 1.3 for counter-flow.