Numerical analysis of lithium-ion battery performance with new mini-channel configurations implementing hybrid nanofluid

Abstract

Background

The thermal management of lithium-ion battery packs was thoroughly investigated in the current study, aiming to enhance cooling efficiency through innovative design approaches. This research evaluates the performance of four distinct mini-channel configurations—Smooth (simple rectangular), Grooved, Tooth, and Pin Fin—integrated with a hybrid nanofluid composed of water and Fe₃O₄-SWMCT nanoparticles.

Methods

These advanced cooling channels are designed to improve thermal regulation by optimizing the thermal characteristics of the system. The study employs a conduction-based model to simulate the unsteady heat source conditions representative of battery discharge cycles. Validation against published data confirms the high accuracy of the modeling approach.

Significant findings

Results demonstrate that the incorporation of nanoparticles in the cooling fluid contributes to a slight reduction in battery temperature, with cells located near the cooling channels exhibiting more uniform temperature distribution. Notably, the channel configuration with Pin fins proves to be the most effective, achieving a Nusselt number 5.03 times greater than that of the Smooth rectangular duct, indicating significantly improved heat transfer performance. Conversely, the channel design with Teeth showed the poorest hydraulic performance, with performance value of 0.84, while the Pin Fin configuration achieved the highest performance value of 2.62, signifying superior overall performance. This study highlights the crucial impact of channel geometry and cooling fluid composition on behavior of battery packs. By advancing the design and material use in cooling systems, the research contributes valuable insights for enhancing battery safety, efficiency, and longevity.