CFD simulation and performance analysis of a biomimetic pompeii worm-inspired thermal management system for EV battery packs

Inspired by the thermotolerant cuticle morphology of the Pompeii worm (Alvinella pompejana), this study develops a biomimetic battery thermal management concept for lithium-ion cells (2.6 Ah, NMC) and assesses its performance against a straight-fin air-cooling baseline of equal footprint under forced-convection conditions. CFD is used to evaluate four fin configurations: no fins, rectangular, stepped, and the suggested biomimetic shape. The 2 C discharge is modelled as an equivalent constant heat-generation model; temperatures are the steady-state maximum cell-surface temperature (Tmax) unless otherwise indicated. The biomimetic design reduces the in-pack temperature spread towards the ≤ 5 °C design target, maintains Tmax within commonly recommended Li-ion operating bands (≈ 20–40 °C), and increases heat flux by 58% (7.3976 W m−2 at 2 C) in comparison to the straight-fin baseline under matched heat load and inlet conditions. In comparison to the straight-fin baseline, it reduces the cell-to-cell temperature spread (ΔT) by 82% within the EV-relevant 10–30 ms−1 airflow region. The area-averaged convective heat-transfer coefficient (h̄) is increased by 73% under the same conditions; the biomimetic geometry maintains ΔT at or below ~ 4 °C in contrast to stepped fins (ΔT ≈ 14.8 °C). In terms of practicality, the architecture is lightweight (about 1.8 kg as opposed to 4.2 kg for a comparable liquid loop) and performs almost independently of direction. In line with the observed improvements in thermal homogeneity and convective heat transfer, flow-field diagnostics demonstrate increased turbulent kinetic energy close to fin tips and cavities as well as improved secondary flows and local recirculation that encourage near-wall mixing.