A Numerical Study on Fluid Flow and Heat Transfer Characteristics according to the Protrusion Installed in the Channel of a U-Shaped Cooling Pad for Electric Vehicle Battery Cooling

In this study, the thermal and flow characteristics of a U-shaped liquid cooling pad for electric vehicle battery modules were investigated by varying the length and spacing of square protrusions attached to the internal channel as well as the coolant flow rate. The protrusions promote vortex formation, thereby enhancing heat transfer within the channel. Moreover, the design parameters were evaluated in two stages. First, the optimal protrusion length was identified based on improved velocity distribution and reduced cell temperature under a single protrusion. Based on the optimized protrusion geometry, multiple protrusions were arranged to determine the ideal spacing that balances the pressure drop and heat dissipation. The simulation results confirmed that the configuration with a protrusion length, spacing, and flow rate of 11 mm, 14.5 mm, and 15 LPM, respectively, provided the most effective cooling. Hence, the battery temperature can be maintained below the 60°C threshold associated with thermal runaway risk.