Authors : Deepak Turkar; Dr. Ajay Kumar Singh; Dr. Parag Mishra; Bhagwat Dwivedi

Volume/Issue : Volume 10 - 2025, Issue 10 - October

Google Scholar : https://tinyurl.com/3356c3m8

Scribd : https://tinyurl.com/5y9pj7hn

DOI : https://doi.org/10.38124/ijisrt/25oct1013

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Abstract : High-energy-density cylindrical lithium-ion batteries, such as 2170 cells, demand efficient thermal management to ensure safe operation, prolonged cycle life, and optimal performance. This study presents a computational fluid dynamics (CFD)-based optimization of a liquid-cooled Battery Thermal Management System (BTMS) incorporating novel triangular-shaped coolant passages positioned between three adjacent cells. The design enhances coolant–cell interaction, improves temperature uniformity, maintains a compact module geometry, and achieves a high volumetric packing efficiency (VPE) of 82.6%. Simulations were performed in ANSYS Fluent 2025 R1 under discharge rates of 1C, 2C, and 5C, with coolant velocities ranging from 0.005 to 0.05 m/s. Results indicate that the triangular channels effectively reduce maximum cell temperature, maintain near-zero temperature difference between cells due to symmetry, and limit pressure drop to below 90 Pa, while increasing the coolant–cell contact area per cell by 43%. These findings demonstrate that the proposed BTMS offers thermally stable, energy-efficient, and manufacturable battery modules suitable for next- generation electric vehicles.

Keywords : Liquid Cooling; Triangular Coolant Channels; Temperature Uniformity; Thermal Optimization; Electric Vehicles; Volumetric Packing Efficiency; 2170 Cells.

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