Experimental and numerical investigations of liquid cooling plates for pouch lithium-ion batteries considering non-uniform heat generation

Ensuring the thermal safety of lithium-ion batteries requires efficient and reliable thermal management systems. However, the non-uniform heat generation of lithium-ion batteries results in uneven temperature distribution, which complicates the comprehension of the flow pattern design and operating parameter optimization in liquid-based battery thermal management, especially under extreme conditions. This study evaluates the thermal management performance of four classic liquid cooling plate designs for pouch batteries by considering their non-uniform heat generation through the electrochemical-thermal coupled model. Through experiment and numerical simulation, the optimal flow pattern is identified. Subsequently, the capability of the thermal management system, utilizing the best flow design, is further assessed under varying operating conditions. The results indicate that while a higher flow rate marginally enhances cooling, the coolant inlet temperature exerts a more substantial impact on the cooling performance. In addition, the recommended parameter settings for cell-level liquid cooling systems are outlined under extreme conditions. With a 5 C discharge rate and an initial temperature of 35 °C, the recommended coolant temperature range and coolant flow rate range are 20–30 °C and 60–100 mL min⁻¹, respectively. As a typical example of computer-aided engineering, this study reveals the impact of battery non-uniform heat generation on battery temperature performance and provides a critical reference for the optimization of liquid-based battery thermal management systems.