APPLIED THERMAL ENGINEERING, cilt.279, 2025 (SCI-Expanded, Scopus)
Developing an efficient battery thermal management system (BTMS) is essential for maintaining the performance and reliability of electric vehicles (EVs). This study proposes a cooling plate design that enhances the cooling plate-battery contact surface area to improve non-uniform heat dissipation in cylindrical battery packs, particularly under high discharge rates (2.0C). Unlike conventional approaches that typically fix the cooling plate height and neglect system weight, this work investigates the effects of varying plate heights (30-60 mm), flow rates (0.1-1.0 L/min), and discharge rates (0.5C-2.0C) in a 6S6P battery configuration. The novelty lies in identifying ideal cooling plate height for different operating conditions through a comprehensive parametric analysis, aiming to ensure effective thermal management while minimizing BTMS weight. Key performance metrics such as peak cell temperature, temperature difference, temperature uniformity, energy efficiency, energy density, and pressure drop are evaluated. The results indicate that, among all the tested operating and design parameters, a cooling plate height of 50 mm gives the best performance for the BTMS at a flow rate of 0.5 L/min. This approach mitigates thermal hotspots, reduces safety risks, and offers a lightweight, efficient BTMS solution for EVs.