Channel design for immersed battery thermal management system based on 3D topology optimization

• Proposes a novel three-dimensional multi-objective TO method. • TO method effectively balances channel's thermal management ability and flow resistance. • Compared with the OC, the pressure drop has decreased by 29.8 %. • The TOC has reduced the minimum inlet flow rate by 57.1 %. • TOC reduces the maximum temperature difference by 14.3 % and the average temperature by 2.86 %. To solve the contradiction between heat transfer efficiency and pressure drop in traditional immersion liquid cooling systems under high rate discharge, this paper proposes a three-dimensional topology optimization (TO) method for the design and enhancement of immersion battery thermal management system (BTMS) channels for 18650 cylindrical lithium-ion batteries. Using multi-objective topology optimization to minimize the average temperature, maximum temperature difference, and pressure drop of the battery. The results showed that after optimization, the minimum flow rate that meets temperature requirements in the channel decreased from 70 mL/min to 30 mL/min, a decrease of 57.1 %, and the pressure drop decreased by 29.8 %. At a flow rate of 60 mL/min, the maximum temperature difference and average temperature decreased by 14.3 % and 2.86 %, respectively. These results demonstrate that the TO method has considerable potential for application in submerged BTMS, providing support for improving the cooling performance of submerged BTMS.