This study presents a bionic structure-based liquid cooling plate designed to address the heat generation characteristics of prismatic lithium-ion batteries. The size of the lithium-ion battery is 148 mm × 26 mm × 97 mm, the positive pole size is 20 mm × 20 mm × 3 mm, and the negative pole size is 22 mm × 20 mm × 3 mm. Experimental testing of the Li-ion battery’s heat generation model parameters, in conjunction with bionic structure and micro-channel features, has led to the development of this innovative cooling system. The traditional bionic liquid cooling plate’s structure is often singular; however, the flow path of the liquid cooling plate designed in this paper is based on the combination of the distribution of human blood vessel branches and the structure of insect wing veins. The external dimension of the liquid cooling plate is 152 mm × 100 mm × 6 mm (length × width × height). Utilizing numerical simulation and thermodynamic principles, we analyzed the heat transfer efficacy of the bionic liquid cooling module for power batteries. Specifically, we investigated the impact of varying coolant flow rates and the contact radius between flow channels on the thermal performance of the bionic battery modules. Our findings indicate that a liquid flow rate of 0.6 m/s achieves a stable maximum surface temperature and temperature differential across the bionic battery liquid cooling module, with a relatively low overall system power consumption, suggesting room for further enhancement of heat transfer performance. By augmenting the contact radius between flow channels, we observed an initial increase in the maximum surface temperature, temperature differential, and inlet–outlet pressure differential at a flow rate of 0.2 m/s. However, at flow rates equal to or exceeding 0.4 m/s, these parameters stabilized across different design Scenarios. Notably, the pump power consumption remained consistent across various scenarios and flow rates. This study’s outcomes offer valuable insights for the development of liquid-cooled battery thermal management systems that are energy-efficient and offer superior heat transfer capabilities.

As a key energy storage component, the rapid detection of battery status and safety and reliability evaluation of the lithium battery have attracted more attention. Among them, the expansion behavior evaluation technology of the lithium battery, as a non-destructive rapid detection method, is an effective means to evaluate the health status of the battery and realize early safety warning. This paper reviews the causes of the current expansion phenomenon of lithium battery, the development status of expansion evaluation technology and the evaluation method of expansion test results. The existing expansion behavior evaluation technology under constant pressure and constant displacement conditions are classified and discussed. By accurately obtaining changes in the internal state of the battery, it can accurately predict and evaluate performance, life and safety. By obtaining the critical conditions of battery expansion, the design and optimization of the module structure are guided. On this basis, the limitations of lithium battery expansion test under different boundary conditions are further discussed. The future development of battery expansion test methods and battery expansion control and solutions are proposed. This paper aims to optimize the evaluation technology of lithium battery expansion behavior and improve the safety and reliability of the battery.