Hydraulic and thermal performance enhancement for the cold plate using topology optimization

Liquid-based battery thermal management system (BTMS) is designed to ensure the narrow operating temperature range for the desired performance of Lithium-ion batteries (LIBs), which ensures the reliable operation of electric vehicles (EVs). Among these, GM Volt design circulates the coolant in a multiple serpentine channeled cold plate, whereas the long flow path makes easily thermal saturation as well as higher pressure drop that requires more pumping power for coolant circulation. We present a cold plate that provides enhanced cooling capacity with reduced pressure drop by multi-constraint topologically optimized design. A series of thermalfluidic numerical validations inclusive of surface temperatures on substrate of cold plate at the fixed pumping power. Compared to the conventional multiple serpentine channels, the pressure drop Delta p decreases dramatically by 90 % at the same mass flowrate, and maximum temperature difference Delta Tmax decreases by 60.8 % at the fixed pumping power, respectively. The optimized design exhibited a significant improvement in 2- or 3-times higher j/f factor at the same Reynolds number.