Study on novel battery thermal management using triply periodic minimal surface porous structures liquid cooling channel

Battery thermal management is a crucial condition for ensuring the safe operation of electric vehicles. The triply periodic minimal surface (TPMS) porous structure boasts high porosity, a large specific surface area, and excellent thermal physical properties. In this study, a novel liquid-cooling channel is designed based on these characteristics. The channel is filled with porous structures and applied in the battery thermal management system (BTMS). Utilizing numerical analysis, compared the cooling performance of liquid-cooling channels filled with different porous structures and investigated the thermal performance of battery modules under diverse factors. The results indicate that the addition of porous structures to the liquid-cooling channel can effectively restrict the maximum temperature of the battery pack and enhance thermal uniformity. Compared to straight tube channel, the Tmax and Delta T of the battery pack with Primitive liquid-cooling structures were reduced by 12.43 % and 8.41 %, respectively. Increasing the volume fraction of the porous structures improves the thermal performance of BTMS, with the best comprehensive performance at a volume fraction of 20 % for the Primitive porous structures. Mass flow rate selection requires attention to the balance between performance and power consumption. Widening the contact angle has the potential to enhance the thermal uniformity of the battery cell, reducing the maximum Delta T of the battery (No.1) from 4.55 degrees C to 3.46 degrees C. In addition, the Primitive liquid-cooling structure demonstrates excellent heat dissipation even under extreme temperature conditions, effectively reducing the risk of thermal runaway due to overheating of the battery.