Heat Transfer and Mechanical Performance Analysis and Optimization of Lattice Structure for Electric Vehicle Thermal Management

With the trend toward integrated development in electric vehicles, thermal management components are becoming more compact and highly integrated. This evolution, however, leads to complex spatial layouts of high- and low-temperature fluid circuits, causing localized heat accumulation and unintended heat transfer between channels, which compromises cooling efficiency. Concurrently, these compact components must possess sufficient mechanical strength to withstand operational loads such as vibration. Therefore, designing structures that simultaneously suppress heat transfer and ensure mechanical intensity presents a critical challenge. This study introduces Triply Periodic Minimal Surface (TPMS) and Body-Centered Cubic (BCC) lattice structures as multifunctional solutions to address the undesired heat transfer and mechanical support requirements. Their thermal and mechanical performances are analyzed, and a feedforward neural network model is developed based on CFD simulations to map key structural parameters to thermal and mechanical outputs. A dual-objective optimization approach is then applied to identify optimal structural parameters that balance thermal and mechanical requirements. Validation via CFD confirms that the neural network-based optimization effectively achieves a trade-off between heat transfer suppression and structural strength, providing a reliable design methodology for integrated thermal management systems.