Jesús Vence, Concepción Paz, Noelia Bouzas, Jorge Caramés

Abstract:

Amidst the notable rise in demand for battery storage technologies, the increasing requirements for high-performance battery systems underscore the imperative for advanced thermal management strategies to optimize reliability, operational efficiency, and safety. In this context, the present study conducts a parametric analysis to optimize micro-channel numbers and cold plate height configurations for improved single-sided thermal management of cylindrical battery cells. Through numerical simulations, the impact of different channel counts and cold plate height reductions on thermal performance and cooling efficiency is evaluated using single-cell configurations and 20S1P battery modules across discharge rates of 2C, 3C, and 5C. The results reveal that a design with 18 channels offers the most effective balance between heat transfer efficiency and operational performance, thereby ensuring effective overall thermal control. Moreover, in the 20S1P battery module scenario, this configuration demonstrates robust thermal management with only marginal temperature increase compared to the 32-channel design, particularly in cells subjected to the highest thermal stress. Furthermore, the analysis of cold plate height variations demonstrates that a 2% reduction in height provides a suitable compromise, offering thermal performance comparable to that of the full-height configuration while also achieving a reduction in weight. In contrast, height reductions exceeding 10% lead to significantly elevated peak temperatures, underscoring the critical importance of maintaining an appropriate contact area between the cold plate and the cell for suitable thermal management.

Keywords: Battery thermal management system, liquid cooling, wavy cold plate, cylindrical cells, electric vehicle.

Date Published: January 12, 2026
DOI: 10.11159/jffhmt.2026.002

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