Numerical Simulation and Optimization of a Novel Battery Box Wall and Contour-Finned Structure in Air-Cooled Battery Thermal Management Systems

Lithium-ion batteries (LIBs) are currently widely used in the electric vehicle sector and have become one of the core components of new energy vehicles. To ensure that the maximum temperature (Tmax) and maximum temperature difference (∆Tmax) remain within acceptable limits after high-rate discharge, this study proposes a novel air-cooled battery thermal management system (BTMS). This BTMS features innovative design elements in its novel battery case walls and contour-following fin structure. Through physical testing of 21,700 LIB discharges and comparative numerical simulations, the accuracy of the simulation model is ensured. Orthogonal experimental analysis is conducted at four distinct levels for each of the four structural factors involved. The final results demonstrate that the novel battery pack wall and contour-shaped fin structure proposed in this paper significantly enhance the heat dissipation capability of air-cooled BTMS. The proposed Model 9 configuration exhibits optimal thermal performance metrics. The Tmax after 3C rate discharge reaches 39.4 °C, with a ∆Tmax of 7.4 °C. This study demonstrates significant application potential in the structural implementation of air-cooled BTMSs.