Performance Evaluation of a Novel Cold Plate with Double-Layer Interdigitated Flow Channels for Battery Thermal Management

Working temperature is a non-negligible factor that determines the operating performance of lithium-ion batteries which are extensively used in vehicles and the energy storage industry. Therefore, it is essential to maintain the battery temperature within an acceptable range while minimizing power consumption and ensuring uniform temperature distribution. To achieve these goals, a novel cold plate design with double-layer interdigitated flow channels is proposed in this study for efficient prismatic battery thermal management. The newly proposed cold plate design outperforms the serpentine-channel based cold plate under the same working conditions, resulting in significant improvements in both battery temperature and pressure drop. Specifically, the maximum temperature and temperature difference were reduced by over 10%, while the power cost was reduced by approximately 50%. By considering different arrangements of inlet and outlet locations, 32 non-repeating designs of the cold plate flow paths were examined. Relatively good inlet and outlet layouts are determined by comparing battery thermal management metrics including the maximum temperature, temperature difference, uniform index, and pressure drop, as well as the overall performance factors that consider both the battery temperature and power cost. In addition, the effects of the inlet flow velocity are examined to determine the optimal design.