Investigating the impact of battery arrangements on thermal management performance of lithium-ion battery pack design

The working temperature is one of the key factors affecting the efficiency and safety performance of automotive power batteries. Current battery pack design primarily focuses on single layout configurations, overlooking the potential impact of mixed arrangements on thermal management performance. This study presents a module-based optimization methodology for comprehensive concept design of Lithium-ion (Li-ion) battery pack. Firstly, the arrangement modules is optimized and performed using particle swarm optimization algorithms considering various arrangement layout (i.e. rectangular, diamond, and staggered arrangements) by taking the intercell spacing and maximum temperature of the modules as design objectives. Secondly, the battery pack configuration design is performed employing a neural network model reflect diverse battery module configurations within the pack, exploring their impact on thermal management performance. The hybrid battery arrangement effectively improves thermal management, and the module spacing helps to enhance heat dissipation. The staggered arrangement has a greater impact on the heat dissipation performance of the battery pack, but the spacing between different modules varies with the position of the modules. When all configuration schemes are staggered modules, the optimal range of the spacing between modules is between 6 and 7 mm. However, the study observes a non-linear relationship between module spacing and the maximum temperature difference within the battery pack. While increasing module spacing initially decreases temperature differences, it eventually reverses, suggesting that spacing alone may not consistently enhance thermal management. Validation with a lithium-ion battery pack case study demonstrates the method’s effectiveness, providing valuable knowledge for future cell and pack designs that employ different battery cell arrangements and diverse cooling strategies.