Topology-Optimized Liquid Cooling Combined with Phase Change Materials for Thermal Management of Large Cylindrical Batteries

ZHANG Da; LIN Zican; SUN Yasong; CAO Huquan; MA Jing

doi:10.7652/xjtuxb202608004

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Topology-Optimized Liquid Cooling Combined with Phase Change Materials for Thermal Management of Large Cylindrical Batteries

Special Topic Thermal Management of New Energy Electric Vehicles | 更新时间：2026-07-28

- Topology-Optimized Liquid Cooling Combined with Phase Change Materials for Thermal Management of Large Cylindrical Batteries
- Journal of Xi'an Jiaotong University Vol. 60, Issue 8, Pages: 45-55(2026)
- 作者机构：
  
  长安大学陕西省交通新能源开发、应用与汽车节能重点实验室，710064，西安
  长安大学西安市交通先进动力重点实验室，710064，西安
  西华大学四川省新能源汽车智能控制与仿真测试技术工程研究中心，611130，成都
  同济大学上海市地面交通工具空气动力与热环境模拟重点实验室，201804，上海
  长安大学汽车学院，710018，西安
- 作者简介：
- 基金信息：
- DOI：10.7652/xjtuxb202608004
  CLC： TK124
- Received：11 December 2025，
  
  Online First：16 March 2026，
  
  Published：10 August 2026
- 稿件说明：
移动端阅览
ZHANG Da, LIN Zican, SUN Yasong, et al. Topology-Optimized Liquid Cooling Combined with Phase Change Materials for Thermal Management of Large Cylindrical Batteries[J]. Journal of Xi'an Jiaotong University, 2026, 60(8): 45-55.
DOI：

ZHANG Da, LIN Zican, SUN Yasong, et al. Topology-Optimized Liquid Cooling Combined with Phase Change Materials for Thermal Management of Large Cylindrical Batteries[J]. Journal of Xi'an Jiaotong University, 2026, 60(8): 45-55. DOI： 10.7652/xjtuxb202608004.

摘要

针对传统大圆柱电池液冷板压降大和均温性差的问题，优化设计了一种结合拓扑优化液冷板与相变材料的热管理系统。首先，基于液冷板与相变材料设计了冷却方案1；其次，针对换热面积受限导致液冷换热性能无法充分发挥的问题，提出了一种增大换热面积的蛇形液冷通道的冷却方案2。最后，利用金属材料的高导热特性，设计了一种基于拓扑优化液冷板、相变材料和导热铝的复合冷却方案3。对比流动和传热性能发现：方案1虽然温度均匀性较好，但电池与液冷板间的换热面积小、相变材料存在无效填充；方案2虽然增大了换热面积，提升了换热性能，但液冷板流阻较大且均温性较差。与上述两种方案相比，方案3的平均温度分别降低了9.11%和4.32%，达到了38.80℃；电池表面温度标准差分别降低了12.51%和23.97%，达到了2.35℃。相较于方案2，方案3的出、入口压降降低了90.08%，达到了33.90 Pa；该研究的优化传热路径及拓扑优化方法将为紧凑空间内的大圆柱电池热管理设计提供新思路。

Abstract

To address the issues of high pressure drop and poor temperature uniformity in traditional liquid cooling plates for large cylindrical batteries

a thermal management system integrating a topology-optimized liquid cooling plate with phase change materials was optimally designed. First

cooling scheme 1 was developed based on the liquid cooling plate and phase change materials. Second

to address the problem that the liquid cooling performance could not be fully utilized due to the limited heat exchange area

cooling scheme 2 was proposed

featuring serpentine liquid cooling channels to increase the heat exchange area. Finally

by utilizing the high thermal conductivity of metallic materials

composite cooling scheme 3 was designed

which integrated a topology-optimized liquid cooling plate

phase change material

and thermally conductive aluminum. A comparative analysis of the flow and heat transfer performance was conducted. It was shown that scheme 1 exhibited good temperature uniformity; however

a limited heat exchange area between the battery and the liquid cooling plate

as well as invalid filling of the phase change material

were observed. For scheme 2

the heat exchange area was increased and the heat transfer performance was improved; however

high flow resistance in the liquid cooling plate and poor temperature uniformity were also observed. Compared with the above two schemes

the average temperature of scheme 3 was reduced by 9.11% and 4.32%

respectively

reaching 38.80℃.The standard deviation of the battery surface temperature was reduced by 12.51% and 23.97%

respectively. Compared with the scheme 2

the inlet and outlet pressure drop of scheme 3 was decreased by 90.08%

reaching 33.90 Pa. The optimized heat transfer pathways and the topology optimization methodology developed in this study provide novel insights for the thermal management design of large cylindrical batteries in confined spaces.

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