Active design of large-scale cooling plates based on multi-objective topology optimization for thermal management applications under Dynamic Stress Test conditions

Liquid cooling plates are widely used in battery thermal management. Current research mainly focuses on small-scale cooling plates designed for individual batteries. However, connecting these small cooling plates at the pack scale poses a high risk of leakage. To address this issue, we propose an active design method leveraging multi-objective topology optimization to maximize heat transfer while minimizing flow energy consumption in the flow channels of large-scale cooling plates. The battery heat generation model was first calibrated through experimental validation, yielding results with a maximum error of less than 3%. Then, a three-dimensional electrochemical-flow-thermal-coupled model was developed to comprehensively examine the effects of different cooling plate structures and inlet flow rates. Findings showed that the cooling plate with two side entrances and two side outlets performed best, achieving a performance evaluation criterion exceeding 1. The optimal flow rate was 2 L/min per inlet, meeting the required temperature-control criteria while minimizing pressure drop to 478.49 Pa. Moreover, we compared this design with conventional cooling plates under Dynamic Stress Test operating conditions. The results showed that the convective heat transfer coefficient of the topology-optimized design reached 353.17 W/(m 2 ·K), a 54.54% increase, while the pressure drop decreased by 54.89%. These findings highlight the promising potential of the topology optimization approach for the active design of large-scale cooling plates in thermal management applications.