Optimisation of thermal management parameters in CFRP battery enclosure with embedded vascular channels


DİKER İ., ÖZKAN G. M., GÖKCİLER O. C., İBEKCİ M. B., ACER D. C., UZAY Ç., ...Daha Fazla

International Communications in Heat and Mass Transfer, cilt.170, 2026 (SCI-Expanded, Scopus) identifier

Özet

This study involves optimizing a Z-type liquid-cooled battery thermal management system (BTMS) with a carbon fiber-reinforced polymer (CFRP) battery enclosure. Thermal management is based on integrated vascular channels that are embedded in CFRP. These channels are produced using a new, patented technique. Using computational fluid dynamics (CFD) analysis and response surface methodology (RSM), the effects of four critical parameters, mass flow rate (ṁ), number of channels (Nc), inlet water temperature (Tin) and the thermal conductivity (k) of the battery case, were investigated, to minimize maximum surface temperature (Tmax) and pressure drop (ΔP). A total of twenty-seven CFD simulation cases were evaluated through the Box–Behnken design methodology. The optimal case with appropriate parameter values (Nc = 19, ṁ = 0.015 kg/s, Tin = 5 °C, k = 0.9 W/m·K) achieved the highest thermal performance (TP = q/ΔP) while keeping Tmax and ΔP at reasonable levels (under 37.3 °C and 2208.1 Pa). Moreover, the variance analysis revealed the most effective parameter on Tmax and ΔP and whether it had a linear or nonlinear effect. This research offers practical insights for electric vehicle battery thermal management systems through advanced thermal management optimization, novel materials, and vascular channel integration.