Optimizing Thermal Management of Lithium-Ion Batteries Using Mini-Channel Cold Plates: Analysis of Cooling Fluids and Flow Rate Variations using CFD
DOI:
https://doi.org/10.59097/jasae.v4i1.72Keywords:
Lithium-Ion Batteries, Thermal Management, Mini-Channel Cold Plate, Computional Fluid Dynamic (CFD)Abstract
Efficient thermal management is critical for improving the safety, performance, and service life of lithium-ion batteries, especially in electric-vehicle applications. This study evaluates a mini-channel cold-plate system by examining the effects of coolant type, mass flow rate, and channel enhancement on heat dissipation using computational fluid dynamics (CFD) supported by experimental validation. Four fluids, namely water, acetone, ethanol, and methane, were examined at mass flow rates of 1×10-5, 1×10-4, and 1×10-3 kg/s. Among the tested fluids, acetone produced the lowest maximum battery temperature of 28.0 °C at 1×10-3 kg/s, while methane showed the weakest thermal performance. Increasing the mass flow rate consistently reduced battery temperature, but it also increased pressure drop and pumping-power demand. The results indicate that coolant selection should be based not only on thermal performance, but also on pumping-power penalty, safety, and environmental considerations. Although acetone delivered the best cooling performance in this study, its flammability limits its immediate practical adoption. The findings provide design guidance for the development of more effective mini-channel cooling systems for lithium-ion batteries.
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