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Investigation on Thermal Performance of a Battery Pack Cooled by Refrigerant R134a in Ribbed Cooling Channels

Author

Listed:
  • Tieyu Gao

    (School of Energy and Power Engineering, Xi’an Jiaotong University, Xi’an 710049, China)

  • Jiadian Wang

    (School of Energy and Power Engineering, Xi’an Jiaotong University, Xi’an 710049, China
    The 703 Research Institute of China Shipbuilding Industry Corporation, Harbin 150010, China)

  • Haonan Sha

    (The 703 Research Institute of China Shipbuilding Industry Corporation, Harbin 150010, China)

  • Hao Yang

    (Vehicle Engineering Institute, Chongqing University of Technology, Chongqing 400054, China)

  • Chenguang Lai

    (Vehicle Engineering Institute, Chongqing University of Technology, Chongqing 400054, China)

  • Xiaojin Fu

    (Vehicle Engineering Institute, Chongqing University of Technology, Chongqing 400054, China)

  • Guangtao Zhai

    (Vehicle Engineering Institute, Chongqing University of Technology, Chongqing 400054, China)

  • Junxiong Zeng

    (Vehicle Engineering Institute, Chongqing University of Technology, Chongqing 400054, China)

Abstract

This study numerically investigates the thermal performance of a refrigerant-based battery thermal management system (BTMS) under various operating conditions. A validated numerical model is used to examine the effects of cooling channel rib configurations (rib spacing and rib angles) and refrigerant parameters (mass flow rate and saturation temperature) on battery thermal behavior. Additionally, the impact of discharge C-rates is analyzed. The results show that a rib spacing of 11 mm and a rib angle of 60° reduce the maximum battery temperature by 0.8 °C (cooling rate of 2%) and improve temperature uniformity, though at the cost of a 130% increase in pressure drop. Increasing the refrigerant mass flow rate lowers the maximum temperature by up to 10%, but its effect on temperature uniformity diminishes beyond 20 kg/h. A lower saturation temperature enhances cooling but increases internal temperature gradients, while a higher saturation temperature improves uniformity at the expense of a slightly higher maximum temperature. Under high discharge rates (12C), the system’s cooling capacity becomes limited, leading to significant temperature rises. These findings provide insights that can aid in optimizing BTMS design to balance cooling performance, energy efficiency, and temperature uniformity.

Suggested Citation

  • Tieyu Gao & Jiadian Wang & Haonan Sha & Hao Yang & Chenguang Lai & Xiaojin Fu & Guangtao Zhai & Junxiong Zeng, 2025. "Investigation on Thermal Performance of a Battery Pack Cooled by Refrigerant R134a in Ribbed Cooling Channels," Energies, MDPI, vol. 18(4), pages 1-27, February.
    • Handle: RePEc:gam:jeners:v:18:y:2025:i:4:p:1011-:d:1595037
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    References listed on IDEAS

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    5. Jia, Zhuangzhuang & Huang, Zonghou & Zhai, Hongju & Qin, Pen & Zhang, Yue & Li, Yawen & Wang, Qingsong, 2022. "Experimental investigation on thermal runaway propagation of 18,650 lithium-ion battery modules with two cathode materials at low pressure," Energy, Elsevier, vol. 251(C).
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