To ensure optimum working conditions for lithium-ion batteries, a numerical study is carried out for three-dimensional temperature distribution of a battery liquid cooling system in this work. The effect of channel size and inlet boundary conditions are evaluated on the temperature field of the battery modules. Based on the thermal behavior of discharging battery obtained experimental measurements, two temperature control strategies are proposed and studied. The results show that the channel width of the cooling plates has a great influence on the maximum temperature in the battery module. It is also revealed that increasing inlet water flow rate can significantly improve the heat transfer capacity of the battery thermal management system, while the relationship between them is not proportional. Lowering the inlet temperature can reduce the maximum temperature predicted in the battery module significantly. However, this will also lead to additional energy consumed by the cooling system. It is also found that the Scheme 5 among various temperature control strategies can ensure the battery pack working in the best temperature range in different depths of discharge. Compared with the traditional one with a given flow rate, the parasitic energy consumption in Scheme 5 can be reduced by around 80%.

In this study, a three-dimensional transient simulation model of a liquid cooling thermal management system with flow distributors and spiral channel cooling plates for pouch lithium-ion batteries has been developed. The cooling plates play the role of uniforming temperature distribution and reducing the maximum temperature within each battery, while the flow distributors have the function of reducing the temperature difference between batteries in the battery module. The accuracy of the thermophysical properties and heat generation rate of the battery was verified experimentally. The optimal structure and cooling strategy of the system was determined by single factor analysis as well as orthogonal test and matrix analysis methods. The optimal solution resulted in a maximum battery module temperature of 34.65 °C, a maximum temperature difference of 3.95 °C, and a channel pressure drop of 8.82 Pa. Using the world-harmonized light-duty vehicles test cycle (WLTC) conditions for a battery pack in an electric car, the performance of the optimal battery thermal management system (BTMS) design was tested, and the results indicate that the maximum temperature can be controlled below 25.51 °C and the maximum temperature difference below 0.21 °C, which well meet the requirements of BTMS designs.