Channel Optimization of Sandwich Double-Sided Cold Plates for Electric Vehicle Battery Cooling

Abstract

Electric vehicle (EV) battery thermal management systems have gradually improved owing to the increasing power demand of EVs. This study aims to optimize the channel geometry of sandwich double-sided cold plates for EV battery cooling under 100% state of charge and 2C-rate charging conditions. For precise and accurate optimization, the conventional one-dimensional analysis model of the sandwich double-sided cold plate was converted into a three-dimensional computational fluid dynamics (CFD) model. Non-dimensional parameters were selected as the main variables of the channel geometry, and nine additional channel shapes were derived based on them. Battery modules with the derived channel shapes were subjected to CFD analysis in the Reynolds number range of 500 to 20,000. The goodness factor was calculated from these correlations, and optimization was performed using the Taguchi method. The results revealed that the wetted area of the channel had a greater impact on battery cooling than the number of channels. This study proposed more generalized design guidelines by employing non-dimensionalized parameters across a wide range of Reynolds numbers. The rectangular channel-based correlations developed in this study showed improved prediction accuracy compared to conventional annular pipe-based correlations and are expected to be applicable to various battery thermal management system designs in the future.