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

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

更新时间：2026-03-11

- Topology-Optimized Liquid Cooling Combined with Phase Change Materials for Thermal Management of Large Cylindrical Batteries
- JOURNAL OF XI’AN JIAOTONG UNIVERSITY (2026)
- 作者机构：
  
  1.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
  2.长安大学西安市交通先进动力重点实验室，710064，西安
  3.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
  4.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
  5.长安大学汽车学院，710018，西安
- 作者简介：
- 基金信息：
- DOI：
  CLC： TK124
- Received：11 December 2025，
  
  Revised：2026-03-11，
  
  Accepted：11 March 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/OL]. JOURNAL OF XI’AN JIAOTONG UNIVERSITY, 2026.
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/OL]. JOURNAL OF XI’AN JIAOTONG UNIVERSITY, 2026. DOI：

摘要

针对传统大圆柱电池液冷板的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 ℃；方案3的出、入口压降分别降低了0%和90.08%，达到了33.90 Pa；方案3的电池表面温度标准差分别降低了12.51%和23.97%，达到了2.35 ℃。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 large cylindrical battery liquid cooling plates

a thermal management system combining a topologically optimized liquid cooling plate with phase change materials was designed. First

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

to overcome the limitation of restricted heat exchange area that hinders the full utilization of liquid cooling performance

cooling scheme 2 was proposed featuring serpentine liquid cooling channels to increase the heat exchange area. Finally

leveraging the high thermal conductivity of metallic materials

a composite cooling scheme 3 was designed integrating the topology-optimized liquid cooling plate

phase change material

and heat-conductive aluminum. Comparative analysis of flow and heat transfer performance revealed: Scheme 1 exhibited good temperature uniformity but suffered from limited heat exchange area between the battery and liquid cooling plate

along with inefficient filling of the phase change material; Scheme 2 increased heat exchange area and improved performance but incurred high flow resistance in the liquid cooling plate and poor temperature uniformity. Compared to the above two schemes

Scheme 3 reduced the average temperature by 9.11% and 4.32%

respectively

achieving 38.80 °C. The inlet and outlet pressure drops of Scheme 3 decreased by 0% and 90.08%

respectively

reaching 33.90 Pa. The standard deviation of the battery surface temperature in Scheme 3 decreased by 12.51% and 23.97%

respectively

reaching 2.35 °C. The optimized heat transfer pathways and topology optimization methodology developed in this study offer novel insights for thermal management design of large cylindrical batteries in confined spaces.

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references

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