采用拓扑优化液冷与相变材料协同的大圆柱电池热管理

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

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33.90Pa；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.

关键词

大圆柱电池 / 液冷板 / 相变材料 / 导热铝 / 拓扑优化

Key words

large cylindrical battery / liquid cooling plate / phase change material / thermal conductive aluminum / topology optimization

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基金资助

陕西省重点研发计划资助项目(2025GH-YBXM-04)

陕西省重点研发计划资助项目(2025CY-YBXM-094)

上海市地面交通工具空气动力与热环境模拟重点实验室开放基金资助项目(VATLAB-2025-7)