Design and optimisation of a novel serpentine flow channel with branch structure

The lithium-ion battery, widely adopted in electric vehicles, demands precise thermal management to ensure optimal performance, longevity, and safety. This study introduces a novel serpentine flow channel with branch structure (SFCWBS) for practical engineering applications. Employing an orthogonal experimental design, the impact of key branch structure parameters, namely inlet angle, width, and confluence position, on thermal balance performance and power loss is thoroughly assessed. The optimised SFCWBS configuration significantly enhances battery pack temperature uniformity while concurrently reducing pressure drop, as revealed by simulation results. The maximum average temperature difference is reduced from 1.16 °C to 0.38 °C, and the pressure drop is reduced from 98.2 kPa to 92.3 kPa.