CFD Modeling and Thermal Analysis of a Cold Plate Design with a Zig-Zag Serpentine Flow Pattern for Li-Ion Batteries

Heavy-duty vehicles, such as trucks or buses, typically have larger battery packs compared to passenger electric vehicles (EVs). These batteries generate more heat due the increased power demands of vehicle. Effective thermal management is therefore crucial prevent excessive buildup and maintain optimal performance. This paper aimed develop a dynamic efficient cooling system for Li-ion used in vehicles. In this study, we propose novel cold plate design featuring zig-zag serpentine flow pattern within rectangular profile channel. The chosen maximizes coolant coverage over plate’s surface area. To investigate performance design, designed modeled total six different plates with varying numbers channels (3, 5, 7, 9, 11, 13). Preliminary simulations were conducted using Star CCM+ software. material selected its high conductivity was aluminum, while water served coolant. Several parameters optimized, including adjustments channel width, mass rate, flux, inlet temperature. optimization determine plate. We found that best configurations five-channel an 18 mm width seven-channel 16 width. It temperature rapidly reached maximum outlet region. three channels, attained at exit region 330.84 K. gradually decreased when number from 3 13 achieved minimum 316 K channels. For these configurations, fluxes 2 °C be optimal, discharge rate 4 deemed acceptable. obtained results are instrumental designing evaluating by exploring various parameters. research contributes development effective large EVs, potentially enhancing their efficiency reliability.