Design and optimization of a dendritic channel cold plate with corrugated walls in battery thermal management system

A novel cold plate featuring bilateral mirrored Y-shaped dendritic channels is developed to optimize coolant distribution for efficient thermal management of square batteries. Based on structural optimization, the dendritic channel design is further combined innovatively with targeted curved protrusions to enhance the comprehensive thermal performance. A new thermogravimetric coefficient f_TGC is introduced to evaluate battery thermal performance, integrating the maximum temperature and temperature difference. The coupling effects of coolant type, channel shape, insulation layer, bifurcation position, and corrugated wall configuration are studied to optimize comprehensive performance. The results show that the thermal efficiency of the cold plate with Y-shaped dendritic channels is improved by more than 6 %, and the battery f_TGC is improved by 7.18 % compared to parallel channels. Compared to serpentine channels, Y-shaped dendritic channels reduce pressure drops from 749.45 Pa and 1722.06 Pa to 145.36 Pa and 322.16 Pa, achieving a reduction of more than 80 %. The insulation layer reduces battery temperature difference by 5.66 °C, and the nanofluid reduces pressure drop by about 53 % and increases the battery f_TGC by about 13 %. The corrugated wall dendritic channel cold plate, prepared by arranging curved protrusions, can further increase the battery f_TGC by about 3.66 %. In general, the dendritic channel cold plate with optimized bifurcated position and corrugated walls exhibits low losses and high cooling efficiency, and provides improved battery temperature uniformity and comprehensive thermal performance, maintaining battery temperature within 37.97 °C and temperature difference within 2.64 °C during 3C discharge. The strategy of multi-structure coupling optimization to enhance heat transfer introduces a new perspective to cold plate design.