What does this research mean for the field?

Increasing airflow and adding fins to a BTMS for 21 700 lithium-ion cylindrical cells significantly improves thermal performance, reducing peak temperature and temperature differences under high discharge rates. Novelty: ClaimNovelty.INCREMENTAL. Consensus alignment: ConsensusAlignment.NEUTRAL.

What question did this study set out to answer?

The central aim is to optimize the thermal management system (BTMS) for lithium-ion cells using computational and statistical approaches.

February 17, 2026

Design and Multiobjective Optimization of Fin‐Assisted Air‐Cooled BTMS for 21 700 Lithium‐Ion Cylindrical Cells Using CFD – RSM Integration

Key Points

The central aim is to optimize the thermal management system (BTMS) for lithium-ion cells using computational and statistical approaches.
Developed a 3D CFD model validated with experimental data.
Evaluated different fin configurations (bare cell, 2 fins, 4 fins, 6 fins) under varying airflow velocities (2–6 m/s) and discharge rates (1C–3C).
Analyzed thermal metrics such as peak temperature, temperature difference, and average temperature using Response Surface Methodology.
C-rate significantly impacts peak temperature, rising from 30°C at 1C to over 100°C at 3C for the bare cell.
Increasing airflow reduces peak temperature by up to 15°C under high C-rates.
The 6-fin configuration lowered peak temperature by 8°C–10°C and temperature difference by up to 4°C compared to the bare cell.

Abstract

ABSTRACT This study presents a comprehensive numerical and statistical investigation of an air‐cooled BTMS for a single 21 700 cylindrical lithium‐ion cell, focusing on the influence of airflow velocity, discharge rate (C‐rate), and longitudinal fin configuration. A 3D CFD model, validated against experimental data, was developed to evaluate four configurations (bare cell, 2 fins, 4 fins, 6 fins) under velocities of 2–6 m/s and C‐rates of 1C–3C. The analysis assessed peak temperature ( T max ), temperature difference (Δ T ), and average temperature ( T avg ) to determine thermal safety and uniformity. Results indicate that C‐rate is the dominant factor, with T max rising from 30°C at 1C to over 100°C for the bare cell at 3C–2 m/s. Increasing airflow from 2 to 6 m/s reduced T max by up to 15°C at high C‐rates, while adding fins improved heat spreading, lowering T max by 8°C–10°C and Δ T by up to 4°C compared to the bare cell. At 3C–6 m/s, a 6‐fin configuration achieved T max ≈60°C and Δ T 0.97, with ANOVA confirming significant main and interaction effects. Multiresponse optimization identified an optimal low‐load condition (2 m/s, 1C, 2 fins) yielding T max = 39.16°C, Δ T = 6.78°C, and T avg = 32.08°C (desirability = 0.798). At high C‐rates, optimal thermal performance required ≥ 4 fins and ≥ 4 m/s airflow. The integrated CFD–RSM approach provides both qualitative flow‐thermal insights and quantitative design guidelines, enabling efficient BTMS optimization for varying load conditions while balancing safety, uniformity, and energy efficiency.

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Cite This Study

Shehabaz et al. (Sun,) studied this question.

synapsesocial.com/papers/699405bb4e9c9e835dfd68b1 https://doi.org/https://doi.org/10.1002/est2.70358

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