Effect of baffle parameters in integrated water tank to mitigate liquid slosh under rapid acceleration

Liquid sloshing in integrated cooling tanks of new energy vehicles under rapid acceleration conditions may significantly compromise system stability. This study investigates the influence of baffle configuration on sloshing dynamics using Coupled Level Set—Volume of Fluid (CLSVOF) method and porous media model. A three-dimensional two-phase flow model was established to simulate a defined acceleration condition (12.3 m/s 2 sustained for 2 s), with particular attention to baffle spacing, immersion depth, and length effects on surface wave characteristics and air entrainment. The results indicate that 20 mm baffle spacing provides effective wave attenuation but increases air entrainment. Baffles positioned at the free surface demonstrate optimal performance in controlling flow turbulence. While extended baffle length reduces turbulent intensity, it promotes greater air entrainment. The proposed configuration utilizing 40 mm spacing with free-surface-aligned baffles achieves an effective compromise between wave suppression and air entrainment mitigation. These findings offer practical insights for the design optimization of cooling system tanks in electric vehicles.