DESIGN AND ANALYSIS OF COLD PLATE FOR THERMAL
MANAGEMENT OF Li-ION BATTERY
Project Phase-1 Report
Submitted to APJ Kalam Technological University
In partial fulfilment of the requirements for the award of Degree
Bachelor of Technology in Mechanical Engineering
Submitted by
JISHNU T (KKE20ME033)
LABEEB AHAMED P(KKE20ME037)
VIVEK T (KKE20ME062)
AMAL SUNIL (KKE20ME065)
Guided by
SUBIN MICHAEL
Department of Mechanical Engineering
DEPARTMENT OF MECHANICAL ENGINEERING
GOVERNMENT ENGINEERING COLLEGE –
KOZHIKODE WEST HILL-673005
PHONE:0495-
238322 NOVEMBER
2023
1
DESIGN AND ANALYSIS OF COLD PLATE FOR THERMAL
MANAGEMENT OF Li-ION BATTERY
Project Phase-1 Report
Submitted to APJ Kalam Technological University
In partial fulfilment of the requirements for the award of Degree
Bachelor of Technology in Mechanical Engineering
Submitted by
JISHNU T (KKE20ME033)
LABEEB AHAMED P(KKE20ME037)
VIVEK T (KKE20ME062)
AMAL SUNIL (KKE20ME065)
Guided by
SUBIN MICHAEL
Department of Mechanical Engineering
DEPARTMENT OF MECHANICAL ENGINEERING
GOVERNMENT ENGINEERING COLLEGE –
KOZHIKODE WEST HILL-673005
PHONE:0495-
238322 NOVEMBER
2023
2
INTRODUCTION
Environmental protection and energy conservation have gained societal acceptance as a
result of the pressures posed by energy scarcity and pollution. In the automotive sector,
plug-in hybrid electric vehicles (PHEVs), hybrid electric vehicles (HEVs), and electric
vehicles (EVs) have drawn interest from all over the world for their benefits in lowering
emissions and energy. An electric vehicle’s power battery is essential to its development.
Lead-acid, lithium-ion (Li-ion), and nickel-metal hybrid (Ni-MH) batteries are among the
multitude of power sources available for electric cars. With its high specific energy and low
self-discharge rate, Li-ion batteries are the most energy-efficient among them, offering
longer cycle life. It is now a sophisticated and widely used component in electric vehicles
as a result.
A massive, high-capacity battery pack is created by connecting thousands of Li-ion
batteries in parallel and series. A lot of heat will be produced and the temperature will rise
when battery cells operate in high-temperature environments and under high rates of
charging and discharging. In reality, variations in temperature can readily affect the
longevity and energy of Li-ion batteries The electrochemical reaction rate of Li-ion
batteries increases exponentially with temperature, in accordance with the Arrhenius theory.
Moreover, heat concentration brought on by the uneven temperature distribution lowers
battery performance. Really, the battery pack will cause conflagration and thermal runaway.
As a result, it’s essential to keep the battery temperature within a suitable range and
preserve a consistent temperature distribution.
Electric vehicles are gradually utilizing the battery thermal management system (BTMS),
which primarily consists of phase change materials (PCMs), liquid cooling, and air cooling.
Air-cooling is the most widely used of these types because of its straightforward design and
reliable operating conditions for small-scale battery packs. Nevertheless, because of the
reduced heat transfer coefficient, air cooling nevertheless results in temperature non-
uniformity. When the materials transition from a solid to a liquid state, the PCMs can
absorb the heat from the battery. Additionally, it can keep the temperature distribution
uniform when the outside temperature approaches the PCM melting point. However, it is
not recommended for prolonged operation. Many studies have been conducted recently on
the liquid cooling system, which has the ability to remove heat from the battery through the
cold plate with internal flowing channels. The most efficient and effective thermal
management system is generally the liquid cooling system, which has the capacity to
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regulate the battery pack’s average temperature between 20 and 45 degrees Celsius.
Currently, a lot of high-performance
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electric cars, like the Tesla Model S, BMW i8, and GM Volt, use liquid cooling systems.
The effectiveness of these cooling systems’ heat dissipation directly impacts the safety of
electric vehicles. Studying the thermal performance of Li-ion battery packs operated in
various conditions is crucial to address a number of issues brought on by the high
temperature of the battery pack, such as reduction in lifespan and thermal runaway.
This paper used simulation to study the thermal performance of a liquid cooling battery
pack using cold plates. With the goal of lowering the battery pack’s maximum temperature
and temperature differential, a three-dimensional computational fluid dynamics (CFD)
model was created. The analysis focused on the effects of cooling liquid mass flow, cold
plate number, channel distribution, and cooling direction on the battery pack’s thermal
behaviour. The purpose of this study is to provide a liquid cooling battery pack design
method by taking cooling conditions and cold plate structural parameters into account.
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BATTERY THERMAL MANAGEMENT SYSTEM (BTMS)
In the world of electric vehicles, the Battery Thermal Management System (BTMS) takes
centre stage, playing a crucial role in balancing the temperature of the battery pack. It goes
beyond just regulating temperature—it helps the battery last longer and ensures it performs
at its best.
METHODS OF COOLING FOR LI-ION BATTERIES
There are different ways to cool Li-ion batteries, each designed to handle the heat generated
during intense use. These methods include:
Air Cooling:
A basic method that uses the surrounding air to cool the batteries. While simple, it may not
be as effective in situations where quick heat dissipation is needed.
Liquid Cooling:
A versatile approach that uses various coolants like water, glycol, and others. This method is
adaptable to different conditions and effectively keeps the temperature in check.
Cooling Using Heat Pipes:
This method uses heat pipes to move heat away from the battery cells, leveraging the
principles of phase change heat transfer.
Cooling with Phase Change Materials (PCMs):
This method utilizes materials that can absorb and release heat during phase transitions,
providing effective temperature control.
Cooling Employing Micro/Mini Channel Cold Plates:
A method that uses small channels to dissipate heat efficiently, maximizing the surface area
for heat transfer.
Cooling with Refrigerants:
An advanced method that uses refrigerants for precise temperature control.
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FOCUS OF THE PROJECT – LIQUID COOLING USING MINI CHANNEL COLD
PLATES (MCPS):
Our project hones in on liquid cooling, specifically using mini channel cold plates (MCPs).
This falls under the category of indirect-contact cooling, a practical choice over direct-
contact methods.
INDIRECT-CONTACT COOLING:
A practical alternative that avoids the limitations of direct-contact methods. It uses a
cooling medium with lower viscosity, like water or glycol, allowing for a more efficient
cooling flow.
SYSTEM CONFIGURATION:
Our chosen liquid cooling system incorporates integrated channels and coolants within the
cooling plates. The heat from the battery is transferred through a metal plate to the flowing
coolant, carried away efficiently by an electric pump.
This project explores the intricacies of liquid cooling through mini channel cold plates,
delving into the dynamic relationship between thermal dynamics and cooling methods in
Li- ion battery systems. It not only focuses on the theoretical aspects but also considers the
practical implications, making it a valuable addition to the ongoing progress in Battery
Thermal Management Systems for electric vehicles.
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LITERATURE REVIEW
Duan, J.; Zhao, J.; Li, X.; Panchal, S.; Yuan, J.; Fraser, R.; Fowler, M. Modelling and
Analysis of Heat Dissipation for Liquid Cooling Lithium-Ion Batteries. Energies 2021[1],
conducted a numerical study, the focus is on achieving optimal working conditions for
lithium-ion batteries through a three-dimensional analysis of temperature distribution in a
liquid cooling system. The study evaluates the impact of channel size and inlet boundary
conditions on the temperature field of battery modules. Two temperature control strategies
are proposed and studied based on experimental measurements of the thermal behaviour
during battery discharging.
The findings highlight the significant influence of the cooling plates' channel width on the
maximum temperature within the battery module. Moreover, increasing the inlet water flow
rate is shown to enhance the heat transfer capacity of the battery thermal management
system, although the relationship between channel width and flow rate is not strictly
proportional.
Lowering the inlet temperature emerges as an effective means to reduce the maximum
predicted temperature in the battery module, albeit at the cost of additional energy
consumption by the cooling system. Among various temperature control strategies, Scheme
5 is identified as ensuring the battery pack operates within the optimal temperature range
across different depths of discharge. Notably, Scheme 5 exhibits an approximately 80%
reduction in parasitic energy consumption compared to the traditional approach with a fixed
flow rate. This study provides valuable insights into the intricate interplay of channel size,
inlet conditions, and temperature control strategies for enhancing the thermal performance
of battery systems.
Jayarajan, S.A.; Azimov, U. CFD modelling and Thermal Analysis of a Cold Plate Design
with a Zig-Zag Serpentine Flow Pattern for Li-Ion Batteries. Energies 2023[2], In
addressing the unique thermal management challenges posed by the larger battery packs in
heavy-duty electric vehicles (Evs), this study focuses on the development of a dynamic and
efficient cooling system for Li-ion batteries. The research proposes an innovative cold plate
design featuring a zig-zag serpentine flow pattern within a rectangular channel, aiming to
maximize coolant coverage over the cold plate’s surface area.
To evaluate the performance of the proposed cold plate design, six different configurations
with varying numbers of channels were designed and modelled. Preliminary simulations,
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conducted using Star CCM+ software, explored the impact of channel width, mass flow
rate, heat flux, and inlet coolant temperature on the cold plate’s effectiveness. Aluminium
was chosen as the cold plate material due to its high thermal conductivity, and water served
as the coolant.
Optimization efforts revealed that the most effective configurations were a five-channel
design with an 18 mm channel width and a seven-channel design with a 16 mm channel
width. The study observed that temperature increased rapidly, reaching its maximum at the
outlet region. The three-channel design exhibited a maximum temperature of 330.84 K,
while an increase in the number of channels led to a gradual temperature decrease, reaching
a minimum of 316 K for the 13-channel design. Optimal heat fluxes of 2 ºC and 3 ºC, along
with a discharge rate of 4 ºC, were identified for these configurations.
The zig-zag design and the corresponding results provide valuable insights for designing
and evaluating the performance of cold plates, considering various parameters. This
research significantly contributes to the advancement of effective cooling systems for large
Li-ion batteries in Evs, with the potential to enhance efficiency and reliability in heavy-duty
electric vehicles.
Tao Deng, Guodon Zhanga, Yan Rana, Ping Liub. Thermal performance of lithium-ion
battery pack by using cold plate. Applied Thermal Engineering 2019[3]. This paper
investigates the critical aspect of thermal performance in lithium-ion battery packs for
electric vehicles. A liquid cooling battery pack comprising four batteries and five cold
plates serves as the experimental setup. The study analyses the effects of cooling liquid
mass flow, cold plate number, channel distribution, and cooling direction on the thermal
behaviours of the battery pack.
The results indicate that a cooling liquid mass flow of 1 g·s⁻¹ is optimal for heat dissipation,
resulting in maximum temperatures of 27.67 °C and 32.17 °C after 3C and 5C discharge,
respectively. The placement of more cooling channels in the middle of the battery pack,
particularly in Design 532, is identified as the most effective heat dissipation condition,
with maximum temperatures reaching 27.59 °C and 31.96 °C after 3C and 5C discharge.
Additionally, the study highlights that a well-considered cooling direction significantly
improves the uniformity of temperature distribution in the battery pack. These findings
offer valuable insights into optimizing the thermal performance of lithium-ion battery packs
in
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electric vehicles, addressing key parameters such as cooling liquid flow, cold plate design,
and channel distribution.
T. Amalesh, N. Lakshmi Narasimhan.”Intr’ducing new designs of mini channel cold plates
for the cooling of Lithium-ion batteries. Journal of Power Sources 2020[4]. This study
introduces seven novel designs of mini channel cold plates (MCPs) tailored for cooling Li-
ion battery modules operating at high C-rates. Through detailed numerical investigations on
a prismatic battery module comprising five 45 Ah Li-ion batteries discharging at 3C rates,
the research aims to discern the impact of channel profile on MCP cooling performance.
The thermal and hydraulic performances of each design are systematically studied and
compared with those of an MCP featuring straight rectangular channels. Notably, all
proposed designs surpass the performance of the basic straight rectangular channels,
effectively cooling batteries to temperatures below 40 °C even under high discharging
conditions. Among the designs, MCPs incorporating zig-zag and circular slot channels
stand out, exhibiting exceptional cooling performance.
These findings underscore the efficacy of the new MCP designs in enhancing cooling
performance for high C-rate discharging in Li-ion battery modules. The superior
capabilities observed, particularly in the zig-zag and circular slot channel configurations,
contribute valuable insights for optimizing thermal management in high-performance Li-ion
battery systems
Tao Deng, Guodong Zhang, Yan Ran. Study on thermal management of rectangular Li-ion
battery with serpentine-channel cold plate. International Journal of Heat and Mass
Transfer 2018 [5]. This study focuses on exploring a simple and efficient liquid cooling
method for rectangular Li-ion power batteries in electric vehicles. The proposed cold plate
features a U- tube shaped serpentine-channel configuration. The investigation analyses the
impact of cooling channel number, channel layout, and inlet coolant temperature on the
cooling performance of the battery thermal management system.
Numerical simulation results highlight the effectiveness of a 5-channel layout in the length
flowing-direction, demonstrating the most efficient cooling performance compared to
layouts with fewer channels. Specifically, this design achieves a notable temperature
reduction of 26 ºC compared to configurations with 2 channels along the width flowing
direction. Additionally, the study reveals that the maximum temperature of the cooling
system increases with higher inlet coolant temperatures. However, there is an identified
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upper limit on the
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number of channels and inlet temperature, balancing efficiency and safety considerations
for the cooling system.
These findings offer valuable insights for the design of cold plates in thermal management
systems for Li-ion power batteries, providing a basis for achieving optimal cooling
performance and ensuring the efficiency and safety of electric vehicle battery systems.
Jianfeng Wang, Xiaodong Liu, Fen Liu, Yiqun Liu. Numerical optimization of the cooling
effect of the bionic spider-web channel cold plate on a pouch lithium-ion battery. Case
Studies in Thermal Engineering 2021[6]. This study addresses the thermal management
system for lithium-ion batteries in electric vehicles, focusing on the insertion of metal plates
with channels on both sides of the battery. Drawing inspiration from the spider-web
structure in nature, the research introduces a novel cold plate design featuring a bionic
spider-web channel. The investigation, conducted at an extreme discharge rate of 12 C,
employs an orthogonal experimental design to assess the cooling performance of this
spider-web channel structure for a lithium-ion battery.
The channel width emerges as the most influential structural parameter affecting the
cooling performance of the cold plate. Conversely, the channel angle exhibits the smallest
influence on cooling effectiveness.
An increase in channel width does not indefinitely enhance cooling performance, with the
most suitable structure identified at a width of 3 mm. A channel angle of 120◦ is determined
to provide the best thermal balance for the pouch lithium-ion battery.
These findings underscore the importance of optimizing structural parameters, particularly
channel width and angle, in the design of the bionic spider-web channel structure. This
research contributes to advancing thermal management systems for lithium-ion batteries in
electric vehicles, emphasizing the need for thoughtful consideration of structural
configurations to achieve effective and efficient cooling.
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OBJECTIVES
The objective of the project is to understand how the channel profile affects the MCPs’
ability to cool.
Create a new BTMS channel design with the following features: improved cycle life,
less pressure drops within the channel, temperature uniformity, and improved cooling
performance.
The effect of the number of channels, inlet mass flow rate, channel width and direction,
and channel distribution on the battery pack’s thermal behaviour needs to be studied.
Create a new 3D model of the modified MCP with a zigzag flow pattern and
rectangular channel geometry.
Use ANSYS Fluent to perform 3D numerical simulations and CFD analysis.
Examine the results regarding the pressure drop and inlet/outlet temperatures within
the channels.
Analysis of Pressure and Temperature Profiles.
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METHODOLOGY
Create a basic MCP design with a straight flow pattern and rectangular channel
geometry for validation and comparison.
Create a comprehensive MCP design with a straight, rectangular channel. For
validation and comparison, use ANSYS Fluent for CFD analysis and 3D numerical
simulations.
Create three-dimensional (3D) models of the newly modified MCP with zigzag flow
and rectangular channel geometry.
Use ANSYS Fluent to run three-dimensional numerical simulations to find the best
design in terms of pressure drop, average temperature, and temperature uniformity.
Compare the findings for the two designs’ inlet/outlet temperatures and the pressure
drop inside the channel.
Examine the cold plate and battery surface’s pressure and temperature contours for
both designs.
Analysis of the obtained results.
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MATHEMATICAL EQUATIONS AND MODELLING METHOD FOR
BTMS
THE GOVERNING EQUATIONS
The mass, momentum, and energy conservations must be satisfied for the fluid flow and heat
transfer in BTMS. In this work, the liquid flow in the straight channels has a Reynolds number
(Re) that is consistently less than 2300, indicating a laminar flow. Convection transfers heat
between the fluid and the cooling plate's channel wall, whereas thermal conduction transfers
heat between the battery cells and the channel walls.
The battery cell's energy conservation equation is as follows:
where ρb, Cb, λb and Vb are the density, specific heat capacity, thermal conductivity and
volume of the battery, respectively, ∇T is the temperature gradient, q is the heat source per
unit volume of the battery. In order to simplify the calculation, ρc, Cc and λc are kept as the
constants.
Similarly, the energy equation of the coolant is described as follows:
where ρc, Cc, λc and u are the coolant density, specific heat capacity, thermal conductivity,
temperature and velocity vector, respectively. Water is used as the cooling medium in
this work.
The governing equations for the fluid flow are outlined as follows. The continuity
equation reads:
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where ρc is the density of the coolant, u is the velocity of the coolant (in vector).
The momentum conservation equation for the laminar flow:
where P is the static pressure, τ is the stress tensor, and g means the acceleration of gravity.
The stress tensor τ is given by:
where µ is the molecular viscosity.
To evaluate the effect of the mass flow rate, the Reynolds number are calculated as
follows:
where υ is the kinematic viscosity of the coolant, d is the characteristic length given by:
BATTERY HEAT GENERATION MODEL
Heat is produced during the battery discharging process by electrochemical reactions,
polarization brought on by the battery's terminal voltage differential, and the movement of
lithium ions and electrons. s. This heat can be classified into the reversible and irreversible
ones. In the experiments, the total heat generation rate of the battery was calculated by the
conservation of heat flow as follows:
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where q total is the total heat generation rate of the battery; q sen is the sensible heat of the
battery; q c represents the heat exchange between the battery and the coolant; q env represents
the heat exchanged between the system and the environment.
INITIAL AND BOUNDARY CONDITIONS
In order to solve the governing equation above, the initial and boundary conditions are applied
as follows: the initial temperature of all computational zones was set to 25 °C. The inlet
boundary condition for the cooling plate was the mass flow rate with a constant temperature,
while the outlet one was the pressure outlet. In the test, the specific inlet mass flow rate will be
given. The inner wall of the cooling plate was fixed by a non-slip boundary condition. The
battery module is modelled to be thermally insulated from the external environment, i.e., the
heat generated by the battery is carried away only by water, while the heat source term is
implemented for the battery cells in the UDF.
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BASE DESIGN MODEL
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CONCLUSION
In summary, the initial phase of this project has been dedicated to the design and simulation
of Microchannel coolers (MCPs) with the primary objective of enhancing their cooling
performance within the context of a battery thermal management system (BTMS). This
phase has been marked by a systematic approach addressing the influence of channel
geometry on cooling efficiency.
The establishment of a baseline design, featuring a simple rectangular channel geometry
and a straight flow pattern, laid a sturdy foundation for subsequent validation and
comparison. This initial design served as a benchmark, enabling the evaluation of
performance improvements achieved in subsequent modifications.
The detailed design phase took a step further by incorporating a straight rectangular channel
into the MCP, not only validating the baseline design but also setting the stage for more
intricate modifications.
A significant advancement came with the optimization through a new channel geometry,
involving the development of a 3D model with a modified rectangular channel featuring a
zigzag flow pattern. The subsequent simulation aimed at determining the optimum design
in terms of pressure drop, average temperature, and pressure uniformity. Preliminary results
indicate promising enhancements in cooling performance.
A critical aspect of this phase involved a comparative analysis between the results obtained
from simulations for both baseline and modified designs. Parameters such as inlet/outlet
temperatures, pressure drop within the channels, as well as temperature and pressure
contours on the cold plate and battery surface were thoroughly analysed. This comparative
study provided a nuanced understanding of the impact of design alterations on MCP
performance.
The successful execution of these tasks demonstrates significant progress in this phase of
the project, offering valuable insights into the parameters influencing MCP cooling
efficiency. Looking ahead, the plan includes further refinement of simulation parameters
and a comprehensive analysis of temperature and pressure contours to guide the subsequent
phases of the project.
This phase holds great significance as it has laid the groundwork for an optimized MCP
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design, showcasing improved cooling performance and temperature uniformity while
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minimizing pressure drop. The success achieved not only contributes to the field of thermal
management but also sets the stage for subsequent experimental validation and potential
real- world applications. Future directions may involve refining the design based on
additional data and exploring practical implementations.
In conclusion, this phase represents a robust progression towards achieving the overarching
goals of the project. The integration of theoretical insights with practical simulations has
provided a solid platform for subsequent phases, positioning the project for further
advancements and meaningful contributions to the realm of battery thermal management
systems.
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REFERENCES
1. Duan, J; Zhao, J.; Li, X.; Panchal, S.; Yuan, J.; Fraser, R.; Fowler, M. Modelling and
Analysis of Heat Dissipation for Liquid Cooling Lithium-Ion Batteries. Energies 2021,
14, 4187.
2. Jayarajan, S.A.; Azimov, U. CFD Modelling and Thermal Analysis of a Cold Plate
Design with a Zig-Zag Serpentine Flow Pattern for Li-Ion Batteries. Energies 2023, 16,
5243.
3. Tao Deng, Guodong Zhanga, Yan Rana, Ping Liub. Thermal performance of lithium-ion
battery pack by using cold plate. Applied Thermal Engineering 2019.
4. T. Amalesh, N. Lakshmi Narasimhan. Introducing new designs of mini channel cold
plates for the cooling of Lithium-ion batteries. Journal of Power Sources 2020.
5. Tao Deng, Guodong Zhang, Yan Ran. Study on thermal management of rectangular Li-
ion battery with serpentine-channel cold plate. International Journal of Heat and Mass
Transfer 2018.
6. Jianfeng Wang, Xiaodong Liu, Fen Liu, Yiqun Liu. Numerical optimization of the
cooling effect of the bionic spider-web channel cold plate on a pouch lithium-ion
battery. Case Studies in Thermal Engineering 2021.
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