Research on Bionic Fish Scale Channel for Optimizing Thermal Performance of Liquid Cooling Battery Thermal Management System

Liquid cooling battery thermal management systems (BTMSs) are prevalently used in electric vehicles (EVs). With the use of fast charging and high-power cells, there is an increasing demand on thermal performance. In this context, a bionic fish scale (BFS) channel structure optimization design method is proposed to optimize the thermal performance. The effects of different structural parameters of the liquid cooling plate in BTMS on its cooling performance, including BFS notch diameter (D), BFS notch depth (H), and BFS notch spacing (S), are investigated. To minimize the maximum temperature (Tmax) and the maximum temperature difference (ΔTmax) as optimization indicators, experimental tests and numerical calculations are performed for a battery pack consisting of 36 square cells. Sixteen sets of thermal performance are discussed for different structural parameters in the transient thermal fluid simulation by using orthogonal tests. Under the optimal structural parameters, Tmax decreases by 1.61 °C (10.8%) and ΔTmax decreases by 0.43 °C (16.7%). In addition, the maximum increase in outlet flow velocity is 2.72% and the pressure is reduced by 4.98%. Therefore, the proposed BTMS will have effective cooling performance in high-power dissipation.