Research on the Cooling Performance of Lithium-Ion Battery Modules with Embedded Phase-Change Material Liquid Cooling Plates in High-Temperature Environments

To address the issues of rapid temperature rise and poor temperature uniformity in high-power battery modules under high-temperature conditions, this study proposes a hybrid battery thermal management system (BTMS) integrating a double-layer Tesla valve cold plate with phase-change materials (PCMs). Based on thermal characteristic experiments of battery cells, a precise battery thermal model was developed, and a Tesla valve reverse-flow channel with excellent temperature control performance was selected. The study compares the cooling performance of single and hybrid cooling methods, proposing double-layer channel composite cooling (DL-PCM). Simulations of the DL-PCM system under dynamic high-temperature and driving cycle conditions show that, compared to existing studies, it reduces the maximum temperature (Tmax) by 4.64% and the maximum temperature difference (ΔTmax) by 24.55% under driving cycle conditions. Furthermore, the effects of coolant parameters (inlet velocity and temperature) on battery pack temperature rise and temperature difference were analyzed. At an ambient temperature of 40°C, the double-layer Tesla valve microchannel cold plate with embedded PCM maintains Tmax at approximately 42°C (3.4% reduction) and ΔTmax below 2.1°C, with a channel pressure drop of only 70 Pa, achieving low energy consumption while ensuring effective cooling performance.