Parametric Study on Water-Cooling Plates to Improve

Cooling Performance on 18650 Li-ion Battery

Advisor
✓ Prof Dr. Jarruwat Charoensuk Presented by Mr.Raksit Nanthatanti ID 64601182
Department of Mechanical Engineering, School of Engineering,
King Mongkut’s Institute of Technology Ladkrabang, Bangkok Taist Tokyo tech student [A2TE15]
10520, Thailand Advanced Automotive and Transportation Engineering in
✓ Dr- Ing.Manop Masomtob International Program
. Energy Innovation Research Group (EIRG), National Energy
Technology Centre (ENTEC), National Science and Technology
Development Agency (NSTDA), Pathum Thani 12120, Thailand
✓ Prof.Dr.Sushiro Hirai
Department of Mechanical Engineering, Tokyo Institute of
Technology, Tokyo, Japan
Introduction Purpose Research Methodology Results and Discussions Conclusions

RESEARCH BACKGROUND[1]

➢ When battery operated, they produce heat inside the

cell.

➢ Increasing temperature is typically the most crucial

factor affecting battery performance and battery life.

➢ The battery's life will shorten as its temperature rises.

➢ Thermal runaway may be triggered, especially at

higher temperatures, leading to fire or explosion. The battery life as the function of lithium-ion battery
temperature retrieved from[A. Greco, X. et al.]

2
 Introduction Purpose Research Methodology Results and Discussions Conclusions

RESEARCH BACKGROUND[cont.]

➢ Water is frequently used as the coolant in liquid

cooling systems.

➢ Due to its practical design and cooling

efficiency, the cooling plate is primarily utilized
in the cooling.
system
➢ The liquid cooling system needs more attention
due to leak and corrosion problems. Symmetry plane

➢ The battery module 5S36P has been developed

at ENTEC The geometry of the cooling channel design with coolant
liquid inside

3
 Introduction Purpose Research Methodology Results and Discussions Conclusions

LITERATURE REVIEW[1]
Heat generation at various C-rate for steady state simulation retrieved from
Kulranut J etal [17]

This figure show summary of the result at various discharge rates retrieved from Kulranut J etal [17]

4
 Introduction Purpose Research Methodology Results and Discussions Conclusions

This fig show Constant Current Control (CC Mode) and Constant Voltage Control (CV
Mode) of the sample 1 at charging 0.75C retrieved from Kulranut J etal [17]

Select CC-mode at SOC= 0.8 [Battery nearly fully charged] Battery has maximum Charging
5
current at 2A
 Introduction Purpose Research Methodology Results and Discussions Conclusions

LITERATURE REVIEW[cont.] (dVoc/dt) can be used to

determine the
Internal Heat generation equation reversible heat
produced by the cell
𝑑𝑉𝑂𝐶 𝑑𝑉𝑂𝐶 throughout the
𝑄𝑔𝑒𝑛 = 𝐼 𝑉𝑂𝐶 − 𝑉 − 𝐼 𝑇 = 𝐼2𝑅 − 𝐼 𝑇
𝑑𝑡 𝑑𝑡 charging/discharging
cycle
I = negative current for charging
dVoc/dt = change in entropy
The state-of-charge (soc) and temperature of the cell affect the open circuit potential
(𝑉𝑂𝐶 ) and internal resistance (R) of the battery. The heating resulting from the Joule
effect (irreversible heat generation) is represented by 𝐼 𝑉𝑂𝐶 − 𝑉
State of charge (SOC)
1
𝑆𝑂𝐶 = 𝑆𝑂𝐶𝑡=0 − ‫𝑡𝑑)𝑡(𝐼 ׬‬
𝐶𝑁

where 𝑆𝑂𝐶𝑡=0 =1 (when the battery is 100% charged)and 𝐶𝑁 is the nominal capacity of
6 the cell
 Introduction Purpose Research Methodology Results and Discussions Conclusions

STATEMENT OF PROBLEM

➢ How do I correctly simulate the flow and heat transfer in

the battery cooling pad when conducting steady and
transient simulations?

➢ Why is varying the number of channels important in the

cooling process of the BTMS system?

➢ How the number of cooling channels and the channel gap

between them influence the water flow distribution and
What is the key parameter that expresses the uniformity The liquid cooling system in Tesla EV vehicle
of channel velocity?

➢ What is the key parameter that affects the cooling

performance of the liquid cooling plate?

7
 Introduction Purpose Research Methodology Results and Discussions Conclusions

PROPERTIES OF MATERIAL

Thermal Conductivity Heat Capacity Density Heat Viscosity

Material Phase
[W/(m.K)] [J/(kg.K)] [Kg/m3] Ratio [Pa.s]

Battery Cell Solid {1.01,1.01,30.22} 750* 2690* - -

Aluminum Solid 155* 893* 2730* - -

Coolant Liquid 0.405* 3300* 1078* 1* 0.00429*

*Retrieved from Masomtob, Manop. (2012). Battery Pack Temperature

Distribution Simulation with COMSOL and MATLAB.
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 Introduction Purpose Research Methodology Results and Discussions Conclusions

The equation below can be used to estimate the heat removal rate from battery cooling
channel

𝐷
Q= 𝑞ሶ =𝑚ሶ 𝑤 𝐶𝑃 (𝑇𝑜 − 𝑇𝑖 ) ; 𝑚ሶ 𝑤 = 𝜌𝜔 𝑣ሶ𝑤 ; A= 𝜋( )2 ; 𝑣ሶ =V*A
2

Q = Heat removal rate of Battery cooling system[kW]

𝑚ሶ 𝑤 = The mass flowrate of Inlet water [kg/s]
𝑣ሶ𝑤 = The volumetric flowrate of Inlet water [m3 /s]
𝜌𝜔 = Density of cooling water =998 [kg/m3]
𝐶𝑃 = Heat capacity of cooling water= 4.187 [kJ/kg·K]
Ti = Inlet temperature [°C] D=4mm
To = Outlet temperature [°C]
V = Velocity Inlet from Boundary condition [m/s]
A = Cross sectional area[m2]
D = Diameter of Inlet cooling Tap(m)

9
 Introduction Purpose Research Methodology Results and Discussions Conclusions

• The steady flow and heat transfer equation for laminar flow

𝜕𝑢 2
𝜌 + 𝜌 𝑢 ∗ ∇ ∗ 𝑢 = ∇ ∗ −𝑝𝐼 + 𝜇 ∇𝑢 + ∇𝑢 𝜇(∇𝑢 + (∇𝑢)𝑇 − 𝜇 ∇ ∗ 𝑢 𝐼 + 𝐹
𝜕𝑡 3

𝜕𝜌
+ ∇ ∗ 𝜌𝑢 = 0
𝜕𝑡

𝜕𝑇
𝜌𝐶𝑝 + 𝜌𝐶𝑝 ∗ u trans∇T = ∇ ∗ 𝑘∇𝑇 + 𝑄𝑔𝑒𝑛
𝜕𝑡
Those Equations will be used in the mode based on heat conjugate heat module.

10
 Introduction Purpose Research Methodology Results and Discussions Conclusions

➢ Investigate the effect of flow parameters and cooling plate configuration on the temperature
distribution of the battery pack.
GOAL
➢ Find the operating conditions that yield uniform of flow distribution, and the temperature of
the battery should be less than 33 °C.
Barrier
Inlet section
Number of cooling channel
Negative terminal of 18650
Cylindrical Battery cell

Outlet section

11
Aluminum Cooling Plate
 Introduction Purpose Research Methodology Results and Discussions Conclusions

There are one hundred-eighty of Li-ion

battery cells in the battery pack. Five
battery modules are packed within
aluminum cooling plates and each
battery module has thirty-six cells

Adjust the Cooling channel

gap to be equal

Vary the number of Cooling

channel on the Aluminum
Cooling plate with Barrier at
Inlet and Outlet section

12 Previous Design
 Introduction Purpose Research Methodology Results and Discussions Conclusions
1-4 step: Flow channel simulation
OVERALL METHODOLOGY 5-7 step: Temperature distribution simulation of Battery Pack

Adoption of the ENTEC cooling pad

1
Conclusion and Discussion design from the 18650 Li-ion battery
model
7
Find the maximum
✓ Different Temperature
temperature of battery
✓ Different Velocity
in final stage
✓ Different number of cooling
channel Specify the problem of cooling
2
6
channels by adjusting the number of
channels and the gap between
channels.
From Kulranut et al. [17]focusing
only on the charging process, the
maximum temperature at the battery

Determine the energy

surface was found at 0.75 C. Steady-state Analysis 3
balance of battery Pack ➢ Flow visualization
➢ Find a pressure drop of ✓ Geometrical Modeling
using conservation
water inside the cooling ✓ Mesh Generation
equation[kW]
channel ✓ Initial and Boundary conditions

5
✓ Solving governing equations
13 4
 Introduction Purpose Research Methodology Results and Discussions Conclusions

FIRST DESIGN OF COOLING CHANNEL

2 Cooling channel base 3 Cooling channel base

design [length 48.125 mm] Barrier Design contain 4 design [length 32.08mm]
25mm
channelbase

205mm
One block of
Middle Base will not count Hence
Channel per base
14
this base devide in half symmetry
 Introduction Purpose Research Methodology Results and Discussions Conclusions

FIRST DESIGN OF COOLING CHANNEL[CONT.]

6Cooling channel base design

4 Cooling channel base design Barrier Design [length 16.042mm]
[length 24.0625 mm]

One block of
Channel per base
15
 Introduction Purpose Research Methodology Results and Discussions Conclusions
167mm*410mm*7.8mm
SECOND DESIGN OF COOLING CHANNEL 3D dimension

Barrier Length 260mm

width 2.5 mm

Cooling channel Length112mm

width 6 mm

74mm 381mm Diameter 4 mm

Barrier Length 160mm
width 2.5 mm 2 channelblock
per base
Ex.The amount of cooling channels
1 2 3 4 5 6 7 8 9 10
inside 2 channelperbase = 10

16
 Introduction Purpose Research Methodology Results and Discussions Conclusions

NUMERICAL ANALYSIS
Initial and Boundary
conditions
• Inlet Condition was varied by inlet velocity and inlet
temperature as shown in table below and Fully
developed was applied in this model.

Parameter1 Parameter2 Parameter3

V_inlet(m/s) T_inlet (°C) number of
Channels per base

0.5 25 2
1.0 30 3
2.0 35 4
3.0 40 6
Inlet and Outlet Condition
was selected both side
17 separately as shown.
 Introduction Purpose Research Methodology Results and Discussions Conclusions

Setting boundary condition of cooling channel inside Liquid cooling Plate

RESEARCH QUESTION
When the number of channels inside cooling plate were 2, 3, 4 and 6
with fixed inlet velocity and inlet temperature of cooling water.
- How the flow is distributed in the cooling-channel plate?
-How the cooling performance is affected

METHOD
-Define domain and Working fluid in geometry[Aluminum and water
as coolant] PARAMETER SETTING
-Runs steady state simulation at fixed inlet velocity=0.5 m/sec and
Temperature = 40C[vary numbers of cooling channels]

EXPECTED RESULT
- Pressure drop at outlet from different conditions above.
- Temperature difference (∆T)plotted with Inlet velocity of cooling
water[m/s]
- Maximum Temperature of each configuration[2,3,4,6 channels]
- Flow Visualization of velocity plot
18
 Introduction Purpose Research Methodology Results and Discussions Conclusions

Point Distribution of Meshes

Liquid cooling plate
Fluid domain : Cooling channel

18650 Li-ion battery

1 block of
Cooling channel

Solid domain : Anodized Aluminum

19
 Introduction Purpose Research Methodology Results and Discussions Conclusions

Mesh Statistics

Description Value

Average element quality 0.6574

Tetrahedron 670752

Pyramid 514

Mesh Generation Prism 21018

Triangle 208732

Quad 2664

Edge element 23704

Vertex element 1107

20
 Introduction Purpose Research Methodology Results and Discussions Conclusions

Setting heat generation as boundary condition in simplified model of battery pack

PARAMETER SETTING

EXPECTED RESULTS
- Temperature at 9th cell when runs at constant heat source
- Show three-dimensional transient problem on 1 Roll of
battery module

Vin=0.03m/s Vout,Qremoved=?
21
 Introduction Purpose Research Methodology Results and Discussions Conclusions

The average velocity at the midpoint of 3 channel is greater than 6 channel

for all case use in simulation

- This graph show comparison between the velocity of

Midpoint in cooling channel with Number of
simulation cases below [3and 6 number of channels]
Case1; Vin=0.5m/sec , T =25C
Case2; Vin=0.5m/sec , T =30C
Case3;Vin=0.5m/sec , T =35C
Case4*;Vin=0.5m/sec , T =40C
Case5; Vin=1.0m/sec , T =25C
Case6; Vin=1.0m/sec , T =30C
Case7; Vin=1.0m/sec , T =35C
Case8;Vin=1.0m/sec , T =40C
Case9*; Vin=2.0m/sec , T =25C >> flows seem to be
more turbulence

22
 Introduction Purpose Research Methodology Results and Discussions Conclusions

RESULT SIMULATION OF STREAMLINE[NUMBER OF CHANNEL=2,3] [V_INLET=0.5M/S ,TINLET=40C]

2channelperbase 3channelperbase
Tin=40.00 C Tin=40.00 C

m/s m/s
Δ𝐏=362.740Pa
Δ𝐏=283.360Pa

This case had higher This case has less

pressure drop than 3 pressure drop and
channel per base. reaches maximum
temperature at
outlet

Tout=43.82 C Tout=43.92 C
23
 Introduction Purpose Research Methodology Results and Discussions Conclusions

RESULT SIMULATION OF VELOCITY STREAMLINE [NUMBER OF CHANNEL=4,6] [V_INLET=0.5M/S ,TINLET=40C]

4channelperbase 6channelperbase
Tin=40.00 C Tin=40.00 C
m/s m/s

Δ𝐏=335.053Pa
Δ𝐏=342.912Pa

When increase
velocity inlet ,
The Temperature
Tout,max=43.78 C trend at outlet side is Tout,max=43.81 C
going down until
adding inlet
temperature
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 Introduction Purpose Research Methodology Results and Discussions Conclusions

PRESSURE DROP RESULT[NUMBER OF CHANNEL=2,3,4,6]

The pressure drop for the 2-channel
14000
2 Channel per Base 3 Channel per Base 4 Channel per Base 6 Channel per Base design is the maximum compared with
12000 other configurations.
10000
High amount of inlet velocity of cooling water The pressure drop for the 3-channel
8000 made a large amount of Pressure drop with
design is the minimum compared with
Pressure drop(Pa)

insignificant effect when increasing number of

6000 cooling channels other configurations
4000

2000
Fixed Inlet velocity and Inlet
Inlet velocity of 0.5 m/s has little effect
on Pressure drop
temperature of cooling water**
0
0.5 0.5 0.5 0.5 1 1 1 1 2 2 2 2 3 3 3 3
-2000

-4000
Velocity Inlet (m/sec)

25
 Introduction Purpose Research Methodology Results and Discussions Conclusions
Conclusions

TEMPERATURE DIFFERENCE (Δ𝑇)RESULTS [NUMBER OF CHANNEL=2,3,4,6]

The number of channels had a slight effect on the

change in temperature difference when comparing the
ΔT of 3-channel design is greater
results by increasing the inlet temperature but fixing than ΔT of 6-channel design except
the inlet velocity at boundary conditions. at Inlet velocity=0.5m/s

High inlet velocity leads

to less temperature
difference

26
 Introduction Purpose Research Methodology Results and Discussions Conclusions

0.04
QRemoved = MbCp(Tout-Tin)

Heat removed
0.03
Example of heat removal rate calculated 0.02
[2channelperbase] by assume that 0.01
pressure constant at outlet channel 0
0 0.5 1 1.5 2 2.5

V_inlet(m/sec)

27
 Introduction Purpose Research Methodology Results and Discussions Conclusions

HEAT REMOVAL CALCULATION WITH DIFFERENT CHANNEL DESIGN[KJ]

Inlet Temperature = 25C Inlet Temperature = 30 C

28 Inlet Temperature = 35 C Inlet Temperature = 40 C

 Introduction Purpose Research Methodology Results and Discussions Conclusions

The standard deviation of channel velocity with various numbers of cooling channels

Previous cooling Design : Use cooling barrier 260 mm

Modified cooling Design : Use cooling barrier 160 mm

29
 Introduction Purpose Research Methodology Results and Discussions Conclusions

Heat generated result in simplified cooling model(Steady state simulation)

Heat flux(w/m2)
Heat conduction theory
Thermal conductivity
depend on T of the material

Heat conduction Tmax=30.707C

Heat flux at
Interface

Heat flux at
Interface

For simulation, Using The average heat generation rate

The Physical Principle for setting Heat X[19187.5 W/m3]≈ 0.307W per 1 cell as a consistent heat
generation in 1 row of Three-dimensional source in steady-state simulation and use Vmin [0.037
model m/s],Inlet temperature =30C[ Inlet conditions in cooling
30 module]
 Introduction Purpose Research Methodology Results and Discussions Conclusions

At 3 channel design this

Tmax=36.5 C < Allow
case has water velocity Temp45 C
inside the channel
Vavg [0.037 m/s]
Vmax [0.042 m/s]
Vmin [0.031 m/s]
Then add Battery heat
generation Q=0.0307W

Temperature plot under steady state circumstances Outlet

inside battery cell using heat source [0.307W]inside
1 cells on one flow channel[9 cells in staggered]

Symmetry plane Negative terminal of

18650Li-ion battery
31
Inlet cells
 Research Methodology
Introduction Purpose Research Methodology Results and Discussions Conclusions

Heat generated result in simplified cooling

model(Transient simulation) Thermal conductivity
Tmax=30.1397C depend on T of the
material

The Physical Principle for setting Heat
generation in 1 row of Three-dimensional
model
32
For simulation, Using the average heat generation rate
[19187.5 W/m3]≈ 0.307W per 1 cell as a consistent heat source in
transient simulation and use Vmin [0.037 m/s],Inlet temperature
=30C[ Inlet conditions in cooling module]
 Introduction Purpose Research Methodology Results and Discussions Conclusions

The result of transient model inside Half Module of Battery using heat source 0.307W[0.75C]

when using an inlet velocity of water of 0.03 m/s and an inlet
temperature of water of 30 °C.
✓ The results of the battery module's greatest temperature
under a 0.75 C charging rate were 54.85 °C.
✓ The maximum temperature difference in the battery was
around 3 °C.
33
when using an inlet velocity of water of 0.03 m/s and an inlet
temperature of water of 40 °C.
The results of the battery module's greatest temperature under a
0.75 C charging rate were 56.85 °C.
The temperature difference of the battery was maximum at 4 °C
[less than the limited value of 5°C].
 Introduction Purpose Research Methodology Results and Discussions Conclusions

The summary of flow dispersion in steady state simulation

✓ A 4-channel design offered the highest velocity uniformity of the water flow distribution among all
channel configurations.
✓ The ability to remove heat from the battery when the inlet velocity increased was consistent. When
using an inlet temperature of 30°C with an inlet velocity of 2 and 3 m/s, It had a slight error at
constant heat removed rate
✓ All cooling designs can produce very good water distribution when using low inlet velocities. However,
when increasing the inlet velocity, the distribution of water in the channel got worse, especially for the
6-channel design, which had the highest standard deviation.

34
 Introduction
CONCLUSIONPurpose
[2] Research Methodology Results and Discussions Conclusions

The summary of heat generation analysis in one row of the battery pack [9 cells][steady-state
simulation]
✓ This result involves developing a three-dimensional thermal model by simulating a battery cooling system. The
detailed temperature distribution of the whole battery pack is demonstrated under normal operating conditions at
under 0.75 C with a maximum heating value of 0.307 W. The highest average temperature at the 9th cell is 30.706
°C, which is lower than the maximum allowable battery temperature(33 °C)
✓ This simplified model yields the highest percentage of battery performance [120%] when using an inlet
temperature of 30°C
The summary of heat generation analysis in one row of the battery pack [9 cells][transient
simulation]
✓ The highest average temperature at the 9th cell for transient simulation is 30.14 °C, running from t = 0 to 3600 sec.
That makes the battery cell temperature in each submodule as close as possible (0.14°C from the result of the
transient simulation).

35