Armanto P. Simanjuntak, J. W. Bae, Benrico Fredi Simamora, Jae Young Lee
The increasing adoption of lithium-ion (Li-ion) batteries in electric vehicles (EVs) and renewable energy systems has heightened the demand for efficient Battery Thermal Management Systems (BTMS). Effective thermal regulation is critical to prevent performance degradation, extend battery lifespan, and mitigate safety risks such as thermal runaway. Liquid cooling has become the dominant strategy in commercial EVs due to its superior thermal performance over air cooling. However, optimizing liquid cooling systems remains challenging due to the trade-off between heat transfer efficiency and pressure drop. Recent studies have explored various coolant selection, nanofluid enhancements, and complex channel geometries, an ideal balance remains difficult to achieve. While advanced methods such as topology optimization offer promising performance gains, they often introduce significant modeling and manufacturing complexity. In this study, we propose a practical alternative: an interconnected straight-channel cooling plate that introduces lateral passages to disrupt the thermal boundary layer and enhance mixing. Comparative analysis shows that the design improves temperature uniformity and reduces peak battery temperature, all while maintaining a moderate pressure drop. The proposed configuration offers a scalable and effective solution for next-generation BTMS, particularly in EV applications where thermal performance and manufacturability are both critical.