Design of Air-Cooling Battery Thermal Management System

Efficient thermal management is essential to maintain the performance, safety, and longevity of battery systems in electric vehicles and other energy storage applications. This report investigates the design and optimization of an air-cooled battery thermal management system (BTMS) for an 8-cell battery module using three duct configurations J-type, Z-type, and U type—to enhance cooling performance. Each configuration was analyzed based on parameters including airflow distribution, cooling effectiveness, temperature uniformity, and pressure drop across the system. Computational Fluid Dynamics (CFD) simulations were conducted to assess the thermal and aerodynamic behaviours of each duct design, aiming to identify the optimal configuration for achieving a balanced temperature profile and reducing hotspot formation. Results indicate that the selected duct shape significantly impacts cooling efficiency, with specific configurations offering superior cooling rates and improved temperature uniformity across cells. This study provides insights into the design considerations for air-cooled BTMS and highlights the practical advantages of tailored duct geometries for thermal management in battery modules.