The investigation and improvement of the cooling process of lithium-ion batteries (LIBs) used in battery electric vehicles (BEVs) and hybrid electric vehicles (HEVs) are required in order to achieve better performance and longer lifespan. In this manuscript, the temperature and velocity profiles of cooling plates used to cool down the large prismatic Graphite/LiFePO₄ battery are presented using both laboratory testing and modeling techniques. Computed tomography (CT) scanning was utilized for the cooling plate, Detroit Engineering Products (DEP) MeshWorks 8.0 was used for meshing of the cooling plate, and STAR CCM+ was used for simulation. The numerical investigation was conducted for higher C-rates of 3C and 4C with different ambient temperatures. For the experimental work, three heat flux sensors were attached to the battery surface. Water was used as a coolant inside the cooling plate to cool down the battery. The mass flow rate at each channel was 0.000277677 kg/s. The k-ε model was then utilized to simulate the turbulent behaviour of the fluid in the cooling plate, and the thermal behaviour under constant current (CC) discharge was studied and validated with the experimental data. This study provides insight into thermal and flow characteristics of the coolant inside a cooing plate, which can be used for designing more efficient cooling plates.

In this paper, an analogous study of the velocity and temperature profiles inside microchannel cooling plates (with hydraulic diameter of 6 mm), placed on a large pouch-type LiFePO₄ battery, is presented using both the laboratory and simulation techniques. For this, we used reverse engineering (RE), computed tomography (CT) scanning, Detroit Engineering Products (DEP) MeshWorks 8.0 for surface meshing of the cold plate, and STAR CCM+ for steady-state simulation. The numerical study was conducted for 20 A (1C) and 40 A (2C) and different operating temperatures. For experimental work, three heat flux sensors were used and were intentionally pasted at distributed locations, out of which one was situated near the negative tab (anode) and the other was near the positive tab (cathode), because the heat production is high near electrodes and the one near the mid body. Moreover, the realizable k-ε turbulence model in STAR CCM+ is used for simulation of the stream in a microchannel cooling plate, and the computational fluid dynamics (CFD) simulations under constant current (CC) discharge load cases are studied. Later, the validation is conducted with the lab data to ensure sufficient cooling occurs for the required range of temperature. The outcome of this research work shows that as C-rates and ambient temperature increase, the temperature contours of the cooling plates also increase.