Cooling Performance Enhancing by Employing Hybrid Pin-Blade Fin Geometry with Constant Weight for Prismatic Lithium-Ion Batteries

This research introduces a novel hybrid pin-blade fin architecture for lithium-ion battery thermal management systems, strategically integrating complementary fin geometries to overcome the traditional thermal-hydraulic performance trade-off. Through comprehensive ۳D CFD simulations, the hybrid design achieves a remarkable dual improvement: maintaining battery temperatures below ۲۱.۵°C during ۵C discharge (۱°C lower than conventional designs) while reducing pressure drop by ۳۰% compared to equivalent pin-fin configurations. The investigation reveals that smaller pin diameters (۲.۵ mm) provide superior thermal performance, while higher blade angles (۸۰°) significantly reduce hydraulic resistance. By combining these optimal features, the hybrid architecture delivers exceptional cooling efficiency while requiring ۷% less aluminum and ۶۶% less coolant than benchmark designs. Quantitative analysis shows that reducing pin diameters from ۱۰ mm to ۲.۵ mm decreases maximum battery temperature by ۰.۳°C, while optimizing blade orientation angles can reduce pressure drop by up to ۶۵ Pa at ۰.۲ l/min flow rate. The innovative cooling plate achieves rapid thermal stabilization within ۱۵۰ seconds and sustains temperature uniformity across the battery surface. This breakthrough approach resolves the long-standing dilemma between thermal regulation and hydraulic penalties in battery cooling systems, establishing a new standard for high-performance, material-efficient thermal management in electric vehicle applications.

کلیدواژه ها:

Hybrid fin architecture ، Hydraulic efficiency ، Prismatic lithium-ion battery ، Cold plate ، Battery thermal management system (BTMS) ، Computational fluid dynamics (CFD)