Synergistic optimization of thermo-hydraulic performance in a double-layer staggered liquid cooling plate integrating streamlined water droplet-shaped flow guide structures

Efficient thermal management is crucial for ensuring the spatial temperature field consistency and battery cycle life of fixed large-scale energy storage systems (CESS). This study designs a novel double-layer staggered liquid cooling plate with an integrated streamlined droplet-shaped flow conduit structure for square lithium iron phosphate (LFP) battery modules, systematically revealing the thermohydraulic synergistic matching mechanism between the “macroscopic interlayer thermal compensation effect” and the “microscopic local Numerical research based on computational fluid dynamics (CFD) methods indicates that the proposed topological structure exhibits excellent control robustness at the flow dynamics level: its morphology shape factor (ξ = 1.75) smoothly fits the laminar flow pressure gradient, firmly controlling the micro pressure recovery coefficient (C pr ) within a very narrow dissipation range around −3.16, deeply cutting the shape resistance cost from the physical bottom layer. At the macroscopic level, the interconnected networks of the upper and lower layers drive the coolant to achieve a self-balancing Thru orthogonal experimental design and analysis of variance (ANOVA), systematic multi-parameter multi-objective optimization further demonstrated that the coolant mass flow rate and conduit width are the dominant factors affecting the thermal-hydraulic synergy performance, both showing extremely high statistical significance (P < 0.01). Under the most adverse baseline conditions of continuous discharge at 1C, the theoretically optimal configuration (A 2 B 2 C 2 ) achieved ultra-low pumping resistance (total pressure drop of only 127.92 Pa) while demonstrating excellent temperature control robustness, effectively maintaining the maximum battery temperature at 29.31°C and keeping the module temperature difference within 2.80 K. This study not only provides an efficient and highly robust structural paradigm for thermal management of high energy density storage, but the introduced dimensionless in-situ decoupling index also offers solid theoretical support for the refined organization of multilayer conjugate heat transfer.