A compact and lightweight liquid-cooled thermal management solution for cylindrical lithium-ion power battery pack

Abstract

Abstract Battery thermal management (BTM) is indispensable to the battery pack of electric vehicles (EVs) for safety. Among different types of BTM technologies, liquid cooling shows its superiority with high heat transfer coefficient and low power consumption. However, the previous works paid little attention to the compactness and weight ratio of liquid-cooled BTM system, which is vital to the specific energy of battery pack. In this study, a compact and lightweight liquid-cooled BTM system is presented to control the maximum temperature (Tmax) and the temperature difference (ΔT) of lithium-ion power battery pack. In this liquid-cooled solution, one thermal conductive structure (TCS) with three curved contact surfaces is developed to cool cylindrical battery. The influences of mass flow rate (mf), inner diameter (d), contact surface height (h) and contact surface angle (α) of the TCS are investigated through numerical study. It is found that for the 5C discharge rate process of battery, Tmax can be maintained within 313 K when mf is larger than 1 × 10−4 kg/s. A weight sensitive factor is defined to evaluate the influences of d, h and α on ΔT and the weight of TCS. It is found that d is the most important parameter that influences the weight. h is the secondary parameter, and α is the parameter with the minimal impact on the weight. Then the values of d, h, and α are designed to reduce the weight of TCS while maintaining its cooling performance. The designed TCS can control Tmax under 313 K with ΔT as 4.137 K. Compared to the original TCS, ΔP, ΔT and the weight are respectively reduced by 80%, 14% and 46% for the designed TCS. Furthermore, the performance of liquid-cooled system with parallel TCSs is discussed. The flow distribution among parallel TCSs is improved through designing the positions of the inlet and the outlet, which enables that Tmax and ΔT of battery pack is similar to the ones of a single battery. The present study facilitates the guideline for compact and lightweight design of liquid-cooled battery thermal management system.