Optimization of Liquid Cooling Channels in BTMS for Cylindrical Lithium-ion Battery Modules: A Review

Efficient thermal management is critical for the performance, safety, and lifespan of lithium-ion batteries in electric vehicles. Cylindrical cells, widely used in EV battery packs, pose significant thermal challenges due to their dense arrangement and high power density. Liquid cooling has emerged as one of the most effective strategies for maintaining uniform temperature distribution in cylindrical-cell modules. This review focuses on the optimization of liquid cooling channels in Battery Thermal Management Systems (BTMS) for cylindrical lithium-ion battery modules. Key studies on channel geometries, flow configurations, coolant types, and hybrid techniques are analyzed. Results indicate that serpentine, spiral, and lattice-shaped channels, when combined with nanofluids or PCM integration, significantly enhance thermal uniformity and reduce maximum cell temperatures. Challenges such as pumping power, manufacturing complexity, and coolant stability are also discussed, along with future research directions emphasizing multi-objective optimization and AI-assisted design.