Addressing the thermal management challenges of prismatic aluminum shell lithium battery modules in electric vehicles under high-rate charge–discharge conditions, this study proposes a multi-objective optimization design method for integrated biomimetic liquid cooling plates. By integrating various highly efficient heat transfer structures from nature, including fractal-tree-like networks, leaf vein branching systems, and spider web radial distribution, a novel biomimetic liquid cooling plate topology was constructed. A multi-physics coupled numerical model considering electrochemical heat generation, thermal conduction, convective heat transfer, and thermal stress deformation was established. The NSGA-II algorithm was employed to globally optimize 12 design variables including channel geometric parameters, operating conditions, and structural dimensions, achieving collaborative optimization objectives of maximum temperature minimization, temperature uniformity maximization, pressure drop minimization, and structural lightweighting. The weight coefficients for the four optimization objectives were determined through the Analytic Hierarchy Process (AHP) with verified consistency (CR = 0.02 < 0.10), ensuring rational priority allocation aligned with automotive safety standards. The optimization results demonstrated that compared to the initial design, the optimal solution reduced the maximum temperature under 3C discharge conditions by 9.9% to 34.7 °C, decreased the temperature difference by 31.3% to 3.3 °C, lowered the pressure drop by 24.6% to 2150 Pa, reduced structural mass by 4.0%, and decreased maximum stress by 16.7%. Quantitative comparison with single biomimetic structures under identical boundary conditions showed that the integrated design achieved a 3.3% lower maximum temperature and 25.7% better flow uniformity than the best-performing single structure, demonstrating the synergistic advantages of multi-biomimetic integration. These synergistic performance improvements can be attributed to the hierarchical multi-scale architecture where fractal networks provide macro-scale flow distribution, leaf vein branches ensure meso-scale coverage, and spider web radials achieve micro-scale thermal matching. Long-term cycling tests conducted at 1C/1C rate with 25 ± 1 °C ambient temperature showed that the optimized design maintained a capacity retention rate of 92.3% after 1000 charge–discharge cycles, demonstrating excellent durability. The complex biomimetic channel structure can be fabricated using selective laser melting technology with minimum feature sizes below 0.3 mm, indicating promising manufacturing feasibility. The research findings provide theoretical guidance and technical support for the engineering design of high-performance battery thermal management systems.
Zheng et al. (Thu,) studied this question.