Improving heat transfer in indirect liquid-based battery thermal management systems through turbulator-equipped conical flow paths

Abstract

To guarantee the safe operation of Li-Ion Cells (LICs) in various applications, such as electric vehicles, an efficient Battery Thermal Management System (BTMS) is necessary. The design of BTMSs, as documented in the literature, typically involves the use of cooling channels with uniform and smooth configurations. However, these configurations encounter the challenge of temperature non-uniformity in the battery module, which stems from elevated coolant temperatures along the flow direction. In this study, a 3D numerical analysis is conducted to develop a novel indirect liquid-based cooling system for the BTMS of a module with cylindrical LICs. The study explores the effects of conical cooling channels, both with and without twisted turbulators, across various coolant mass flows during a 2C discharge process of LICs. Within the studied ranges, diverging cooling channels improve the overall thermal and hydraulic performance of the BTMS by an average of 40%, increasing the heat transfer coefficient by a maximum of 32.6%, and decreasing pressure drop by up to 35.1%. The application of turbulators proves effective in reducing the maximum temperature difference within the LICs, demonstrating a decrease of approximately 34.2% at the minimum mass flow rate and 74.4% at the maximum mass flow rate. This emphasizes the more substantial impact of turbulator utilization at higher coolant mass flow rates. An increased coolant flow rate leads to a significant enhancement of the heat transfer coefficient, ranging from 70.5% to 79.0% for the BTMS incorporating turbulators. Moreover, the study highlights a more pronounced impact of increasing mass flow rates in the BTMS designed with converging cooling channels compared to those designed with diverging channels. Finally, the results of this analysis demonstrate that the proposed system is capable of efficiently regulating the temperature of the entire battery module, ensuring that it consistently maintains a normal and safe operational range suitable for vehicular applications (below 40 °C).