A topology optimization-based-novel design and comprehensive thermal analysis of a cylindrical battery liquid cooling plate

In previous studies, the designs of the liquid cooling channel for battery packs usually paid emphasis on optimizing the predefined cooling channels. This significantly restricts the possibilities for geometric modifications of cooling channels, consequently placing limitations on the potential improvement in heat dissipation performance. To address these limitations, this study proposes a Topology optimization-based-novel design and comprehensive thermal analysis of a cylindrical battery liquid cooling plate. The aim of using topology optimization is to overcome these constraints, enabling more flexible and global domain designs. Three different inlet–outlet configurations of the cooling plate structure were designed using a dual-objective optimization function. A comprehensive numerical analysis was conducted and the topology-optimized liquid cooling plate system was compared with two other cooling pipe liquid cooling systems. The effects of coolant flow rate, battery discharge rate, and cooling plate thickness and quantity on the heat dissipation performance of the liquid cooling system were investigated. Findings demonstrate that the topology-optimized cold plate system with four inlets and two outlets exhibits optimal heat dissipation performance. Increases in coolant flow rate, cold plate thickness, and quantity contribute to enhanced cooling performance of the liquid cooling system. Taking into account factors such as pump power consumption, system weight, and heat dissipation performance, a liquid-cooled system with three cold plates and an inlet flow rate of 2.5 × 10^-6 m³/s is considered the optimal choice for cooling the battery pack in this study. Under the cooling of this cold plate system, at a coolant and ambient temperature of 25 °C and a discharge rate of 3C, the battery pack's maximum temperature and temperature difference are 30.9 °C and 4.87 °C, respectively.