Thermal Management of Lithium-Ion Battery with Novel Aero-Fins: A Numerical Study

Lithium-ion batteries are critical for electric vehicles, and an effective battery thermal management system (BTMS) is essential for optimal performance and lifespan of the battery. Air-cooled BTMS is applicable to low-power battery packs, but it results in increased average cell temperature along the flow direction. The present study proposes a novel BTMS with straight aero-fin (SAF), inclined aero-fin (IAF), alternate inclination of aero-fins (AIAF), and gradually inclined aero-fin (GIAF) designs with aero-fins surrounding each cell of an air-cooled battery pack. A mathematical model is developed for the proposed BTMSs and simulated at the inlet temperature and velocity of [Formula: see text] and 1 m/s, respectively, and 3 C discharge of the cells. Results indicate that higher angles of attack reduce the maximum temperature and temperature differences, with an increased pressure drop. IAF and AIAF configurations with [Formula: see text] operate with safe maximum temperatures of [Formula: see text] and [Formula: see text], respectively, and corresponding temperature differences of [Formula: see text] and [Formula: see text]. The AIAF configuration with a [Formula: see text] angle of attack satisfies the desired thermal limits with the least pressure drop. The average temperature is reduced by [Formula: see text] in configurations with [Formula: see text] than SAF. The desired temperature limits were not maintained by SAF and GIAF configurations.