Thermal management characteristics of lithium-ion batteries based on spring baffle design

To address the issues of elevated temperature and poor temperature uniformity in battery modules during high-intensity operation when using traditional parallel flow channel liquid cooling plates, this study proposes a biomimetic fin liquid cooling plate integrated with spring baffles. Numerical simulations were conducted to compare the performance differences between the proposed cooling plate and conventional parallel channel designs. The effects of three inlet clearances ( H 1 , H 2 , and H 3 ) of the spring baffles on cooling performance were systematically investigated, and the optimal parameters were determined through orthogonal experiments. The results indicate that the influence of inlet clearance on cooling performance follows the order: H 3 > H 1 > H 2 . Under the optimal configuration (Case 5-2: H 1 \(= 2.5\,mm\) , H 1 \(= 5.0\,mm\) , H 3 \(= 7.5\,mm\) ), significant improvements were achieved compared to the conventional system. Specifically, the maximum temperature decreased by \(2.312\,∘C\) ( \(8.027%\) ), and the maximum temperature difference was reduced by \(2.055\,∘C\) ( \(77.811%\) ), while the pressure drop increased slightly by \(6.081\,Pa\) ( \(2.183%\) ). These results demonstrate that the proposed design effectively enhances thermal performance while maintaining a relatively low hydraulic penalty, providing a promising solution for battery thermal management applications.