Optimization of fin parameters in cooling systems for temperature uniformity enhancement in battery module applications with offset strip fins

The efficient thermal management of Lithium-ion batteries (LIBs) stands as a critical factor in ensuring the reliable operation of electric vehicles. For managing multiple LIB modules, a common approach involves utilizing a cold plate for mounting. It has been suggested that this interspersed design proves more effective, especially for large-scale battery packs, in achieving smoother overall cooling performance and temperature uniformity. Consequently, we need a new cold plate design that not only enhances thermal performance for batteries emitting higher thermal loads but also ensures more uniform temperature distributions across battery surfaces, all while maintaining simplicity in manufacturability. In this study, we introduce a new cold plate design employing offset strip fins (OSFs) cores. We assess its thermal and hydraulic performance using objective functions such as the Colburn factor (j) and Fanning friction factor (f). Through optimization techniques, we determine the optimal shape parameters that maximize heat transfer rates on the cold plate, with only a marginal increase in pressure drop. This optimized configuration is then compared with both the baseline common cold plate and a reference OSFs cold plate. The results show a significant reduction of up to 32.3% in maximum temperature differences, signifying an improved temperature uniformity achieved with this new design.