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Maintaining the peak temperature of a battery within limits is a mandate for the safer operation of electric vehicles. In two-wheeler electric vehicles, the options available for the battery thermal management system are minuscule due to the restrictions imposed by factors like weight, cost, availability, performance, and load. In this study, a multi-strategical cooling approach of forced convection and mist cooling over a single-cell 21,700 lithium-ion battery working under the condition of 4C is proposed. The chosen levels for air velocities (10, 15, 20 and 25 m/s) imitate real-world riding conditions, and for mist cooling implementation, injection pressure with three levels (3, 7 and 14 bar) is considered. The ANSYS fluent simulation is carried out using the volume of fluid in the discrete phase modelling transition using water mist as a working fluid. Initial breakup is considered for more accurate calculations. The battery's state of health (SOH) is determined using PYTHON by adopting the Newton–Raphson estimation. The maximum temperature reduction potential by employing an airflow improviser (AFI) and additives (Tween 80, 1-heptanol, APG0810, Tween 20 and FS3100) is also explored. The simulation results revealed that an additional reduction of about 11% was possible by incorporating additives and AFI in the multi-strategical approach. The corresponding SOH improvement was about 2%. When the electric two-wheeler operated under 4C, the optimal condition (Max. SOH and Min. peak cell temp.) was achieved at an air velocity of 25 m/s, injection pressure of 7 bar with AFI and 3% (by wt.) Tween 80 and a 0.1% deformer. [ABSTRACT FROM AUTHOR]

Elevated battery temperature and its heterogeneity are responsible for many battery‐related problems such as short lifespan and thermal runaway. For longer life and safe functionality of lithium‐ion battery (LIB), both the average battery temperature and temperature heterogeneity must be controlled. The present work analyzes a modified cooling channel design that can control both the average battery temperature and its heterogeneity. The design adopts microtexturing approach for the heat transfer augmentation of the serpentine cooling channels. First, the transient thermal analysis of different geometry of microtextures, viz., microchannels (MCs) and microdimples (MDs), is carried out on an aluminum slab. The rectangular MCs and square MDs are found to be the most efficient among the other considered microtexture geometries. Further, the modified design is employed for a 19‐cell battery pack to analyze the thermal performance, pressure drop, and coolant pump power requirements. A decrease in maximum temperature difference (MTD) by 6.03 % and 3.72% is observed for 380 MCs (rectangular) and 960 MDs (squared), respectively. While MDs improve the temperature homogeneity within the LIBs, the coolant pump power requirement and pressure drop (by ≈15.42%) are higher for it compared to the MC‐based design for a given MTD. [ABSTRACT FROM AUTHOR]

Battery design efforts often prioritize enhancing the energy density of the active materials and their utilization. However, optimizing thermal management systems at both the cell and pack levels is also key to achieving mission-relevant battery design. Battery thermal management systems, responsible for managing the thermal profile of battery cells, are crucial for balancing the trade-offs between battery performance and lifetime. Designing such systems requires accounting for the multitude of heat sources within battery cells and packs. This paper provides a summary of heat generation characterizations observed in several commercial Li-ion battery cells using isothermal battery calorimetry. The primary focus is on assessing the impact of temperatures, C-rates, and formation cycles. Moreover, a module-level characterization demonstrated the significant additional heat generated by module interconnects. Characterizing heat signatures at each level helps inform manufacturing at the design, production, and characterization phases that might otherwise go unaccounted for at the full pack level. Further testing of a 5 kWh battery pack revealed that a considerable temperature non-uniformity may arise due to inefficient cooling arrangements. To mitigate this type of challenge, a combined thermal characterization and multi-domain modeling approach is proposed, offering a solution without the need for constructing a costly module prototype. [ABSTRACT FROM AUTHOR]

In this study, we present an innovative, fully automated, and digitalized methodology to optimize the energy efficiency and cost effectiveness of Li-ion battery modules. Advancing on from today's optimization schemes that rely on user experience and other limitations, the mechanical and thermal designs are optimized simultaneously in this study by coupling 3D multi-physical behavior models to multi-objective heuristic optimization algorithms. Heat generation at various loading and ambient conditions are estimated with a physics-based, fractional-order battery cell-level model, which is extrapolated to a module that further accounts for the interconnected cells' heat transfer phenomena. Several key performance indicators such as the surface temperature increase, the temperature variations on the cells, and heat uniformity within the module are recorded. For the air-cooled study case, the proposed coupled framework performs more than 250 module evaluations in a relatively short time for the whole available electro-thermal-mechanical design space, thereby ensuring global optimal results in the final design. The optimal module design proposed by this method is built in this work, and it is experimentally evaluated with a module composed of 12 series-connected Li-ion NMC/C 43Ah prismatic battery cells. The performance is validated at various conditions, which is achieved by accounting the thermal efficiency and pressure drop with regard to power consumption improvements. The validations presented in this study verify the applicability and overall efficiency of the proposed methodology, as well as paves the way toward better energy and cost-efficient battery systems. [ABSTRACT FROM AUTHOR]

In this study, a comprehensive simulation study was carried out to obtain detailed battery temperature behaviors. The influences of air inlet temperature, air flow rate, C‐rate, and free stream temperature were investigated on the temperature uniformity and maximal battery temperature. Taguchi design is implemented to investigate the main effects of four control parameters in the battery thermal management process. Results indicated that as the free stream temperature (delta = 7.3366) was the most influential factor for the temperature uniformity, the air inlet temperature (delta = 0.2679) was the most efficient factor for the maximal battery temperature. The contribution of the air inlet temperature was 28% and 38% for temperature uniformity and maximal battery temperature, respectively. Additionally, the free stream temperature contributed 32% to temperature uniformity and 25% to the maximum battery temperature. The airflow rate was found to be the least effective factor for temperature uniformity (delta = 2.8672) and maximal battery temperature (delta = 0.0506). The results could be helpful in the design of a lithium‐ion battery thermal management process to improve temperature uniformity and maximal battery temperature. [ABSTRACT FROM AUTHOR]

The significant heat generated during the operation of lithium‐ion batteries raises the battery temperature thereby leading to performance degradation and thermal runaway in a thermal abuse environment. Therefore, a simple but effective battery thermal management system (BTMS) is crucial to achieve the permissible operating temperatures. In this work, the performance of air‐cooled BTMS is evaluated by changing the arrangement of cells under discharging conditions. Seven distinct arrangements (trapezoidal, slanted, cross, aligned, staggered, tilted square, and zigzag) of lithium‐ion cells are investigated in a rectangular battery pack. Two‐way coupling of 1D electrochemical model and 2D conjugate thermal‐fluid model is employed. The increasing Reynolds number reduces the cell temperature due to augmented convective effects. Under otherwise identical conditions, the zigzag cell arrangement outperforms the other cell arrangements but at the expense of the highest pressure drop (≈threefold). Particularly, the values of average and maximum cell temperature are reduced by ≈5K and ≈4K, respectively, for Re = 1000 at 1C in comparison to the aligned cell arrangement. Similarly, the least favorable performance is predicted by the trapezoidal, slanted, and cross‐cell arrangements. Finally, a performance plot is suggested considering the trade‐off between the power requirement and the cooling enhancement. [ABSTRACT FROM AUTHOR]

This paper introduces a novel hybrid thermal management strategy, which uses secondary coolants (air and fluid) to extract heat from a phase change material (paraffin), resulting in an increase in the phase change material's heat extraction capability and the battery module's overall thermal performance. A novel cold plate design is developed and placed between the rows and columns of the cells. The cold plate contains a single fluid body to improve the thermal performance of the battery module. Experimental studies were conducted to obtain the temperature and heat flux profiles of the battery module. Moreover, a numerical model is developed and validated using the experimental data obtained. The numerical data stayed within ±2% of the experimental data. In addition, the ability of nanoparticles to increase the thermal conductivity of water is examined and it is found that the cooling from the liquid cooling component is not sensitive enough to capture the 0.32 W/m K increase in the thermal conductivity of the fluid. Furthermore, in order to enhance the air cooling, fins were added within the air duct to the cold plate. However, this is not feasible, as the pressure drop through the addition of the fins increased by ~245%, whereas the maximum temperature of the battery module reduced by only 0.6 K. Finally, when scaled up to an entire battery pack at a high discharge rate of 7 C, the numerical results showed that the overall temperature uniformity across the pack was 1.14 K, with a maximum temperature of 302.6 K, which was within the optimal operating temperature and uniformity ranges. Therefore, the developed thermal management strategy eliminates the requirement of a pump and reservoir and can be scaled up or down according to the energy and power requirements. [ABSTRACT FROM AUTHOR]

A phase change materials (PCM) coupled mini-channel cooling plates model was established for the optimization of the battery thermal management system (BTMS). Specific cooling strategies with different discharge rates of the battery were discussed. For a discharge rate of under 2C, using PCM can meet the heat dissipation needs. Particularly, for a discharge rate below 1.2C, external cooling was not necessary. For a discharge rate above 2C, active cooling should be added to compensate for the lack of heat storage of PCM. In the research of optimization structure, it was found that the scheme of four cooling plates and each cooling plate with two mini-channels was the most ideal in this research, which not only reduced the battery temperature efficiently but also maintained a good temperature uniformity of the battery. For the optimization parameters, the effect of the ethylene glycol solution temperature, ethylene glycol solution volume fraction and the start-up time of active cooling on the maximum temperature of the battery and the melting fraction of PCM were discussed. After the multi-factor parameters optimization by Response Surface Methodology, three optimization schemes were put forward, which could reduce the driving power consumption by 35% – 40%. The research could provide valuable information support and optimization suggestions for the design of BTMS.

The in-depth research on the heat exchanger for lithium-ion batteries is of significant importance due to its crucial role in ensuring the safe operation of electric vehicle (EV) power systems. To enhance the thermal and flow characteristic of the heat exchangers, the novel heat exchangers for 18650-cylinderical lithium-ion batteries have been proposed by topology optimization with the minimization of pressure drop and the lowest average temperature (∏ 1) and the minimization of pressure drop and the lowest temperature difference (∏ 2) as two different optimal goals. The topology optimization based on the variable density method is utilized to get two-dimensional (2D) optimal channels, and then the optimized results are extended to three-dimensional (3D) heat exchangers. The 3D heat exchangers are named TOHE-1 which is gotten by stretching the topology channels with ∏ 1 as optimal goal and TOHE-2 which is gotten by that with ∏ 2 as optimal goal. Subsequently, a detailed thermodynamic analysis is performed to assess the effect of the type of heat exchangers, channel heights, weight factor of topology optimization function, mass flow rates and discharge rates on the cooling effect of the batteries. The results show that compared with the traditional channel heat exchangers, the heat transfer coefficient of topological heat exchangers have increased by 49.92%, while reducing pressure drop by 27.81%. Meanwhile, compared to TOHE-1, heat transfer coefficient of TOHE-2 is increased by 9.70%, while pressure drop is saved by 4.70%. Other studies have indicated that for a 4 C discharge of the battery, a topological heat exchanger with a channel height of 1.5 mm, a thermal performance weight factor of 0.1, and a mass flow with 3.3 × 10−3 kg s−1 is the optimum heat dissipation scheme. Finally, the numerical studies are verified by conducting the convective heat transfer experimental tests. [Display omitted] • The topology optimization heat dissipation scheme for cylindrical lithium batteries is proposed. • The performance of topological heat exchangers is studied numerically and verified experimentally. • The performance of different functional types of topological heat exchangers is compared. • The ratio of heat dissipation scheme to battery weight is considered in cooling scheme design. [ABSTRACT FROM AUTHOR]

• Design for hybrid battery pack with high energy density and high safety. • Thermal Management Optimization Layout Design for Hybrid Battery Packs. • The P2D model is used to study electrochemical properties of single battery. • Multiphysics coupling analysis of electro-thermal behavior. • The SOC estimation method for hybrid battery pack. As traditional battery systems, lithium iron phosphate (LFP) batteries have better safety but lower energy density and nickel manganese cobalt oxide (NMC) batteries have higher energy density but poorer safety. In this work, we design a hybrid battery pack that has both higher energy density and higher battery safety. By analyzing the thermal properties of battery packs with aligned, staggered, and staggered arrangements, it can be concluded that the aligned arrangement has superior cooling efficiency and space-efficient optimization compared to the other arrangements, which have shorter flow paths to minimize air energy loss and reduce pressure drop. Notably, we design the optimal arrangement to avoid placing the NMC cells near the air outlet, to avoid NMC concentration, and to decentralize the LFP cells to reduce the relatively high maximum temperature and temperature difference. This hybrid battery pack is expected to give a boost to lithium-ion battery applications. [ABSTRACT FROM AUTHOR]

To maintain the optimal operating temperature range for the power batteries of new energy vehicles, this paper proposes a novel tree-structured channel cold plate. An orthogonal experimental approach was employed to investigate the effects of inlet flow rate m, inlet channel quantity n, channel width d, and hierarchy ratio α on battery temperatures T max , standard temperature difference T σ , and pressure drop Δ P. Non-dominated sorting genetic algorithm II (NSGA-II) was utilized to obtain an optimized solution set. The results reveal that the tree-like cold plate configuration including m = 15 g/s, n = 7 and 8, d = 3 mm, and α = 1:2:1 demonstrates superior performance. Thus, the developed cold plate was further compared with the conventional straight-through cold plate design. The results indicate that the proposed tree-like cold plate exhibits the maximum decreases of 13.94% in T max , 52.94% in T σ , and 61.5% in Δ P. The most significant improvement in the composite indicator PEC was 89%. In conclusion, the tree-like channel cold plate developed in this study provides excellent heat dissipation capability for power batteries, offering valuable insights for the thermal design of battery liquid cooling systems. [ABSTRACT FROM AUTHOR]

An optimization workflow combining Latin hypercube sampling (LHS), surrogate models and multi-objective optimization is explored and applied to augment the effectiveness of a hexagonal mini-channelled cooling plate proposed previously in mitigating the overheating issues of 20Ah pouch batteries. Three design parameters are selected and deliberately randomized to explore a range of geometric configurations that might not be readily apparent through traditional intuition. Alongside, two thermo-fluidic parameters are varied with an optimization objective to minimize maximum battery temperature, pressure drop and enhance heat transfer performance simultaneously. Initially, 160 sample points are generated using LHS, followed by simulations conducted using COMSOL Multiphysics for a fixed discharge rate of 3C and an ambient temperature of 35 °C. Then, Multi linear regression, Response surface approximation, Support vector machine, and Kriging model are considered in search of the best surrogate. Results highlighted that the Kriging model could make predictions more accurately and is used further. Later, a Pareto analysis is performed using non-dominated sorting genetic algorithm II to generate 100 optimal solutions influencing the three conflicting objectives. Finally, the best compromise solutions are obtained using a K-means clustering algorithm and are numerically validated. The case with a side length of 18.99 mm, a channel width of 4.99 mm, a branching angle of 91.51° and a coolant temperature of 25 °C is ideal. This aided in reducing the pressure drop by 62.32% and enhancing heat transfer coefficient by 64.41%, with a minimal change in maximum temperature compared to that of the initial design under the same mass flow rate limit of 0.003 kg s−1. In addition, the SHapley Additive exPlanations technique is employed to unravel the design and operating variable's impact on the objective functions. Overall, the proposed framework could be a valuable contribution to optimizing the cooling channel design and potentially boosting the battery lifespan. [Display omitted] • Performed multi-objective optimization of hexagonal cold plate design for Li-ion battery. • Identified Kriging as the superior model with a higher R2 value for different cases. • Implemented NSGA II to get optimal design, forming a balance amid conflicting goals. • SHAP insights in assessing the feature impact in the machine learning prediction. [ABSTRACT FROM AUTHOR]

The discharge performance of lithium-ion batteries (LIBs) is severely degraded at low temperatures. The existing LIBs preheating systems face challenges including high costs and consumption of battery capacity. Therefore, this paper developed an innovative electrically-controlled crystallization electrode based on calcium chloride hexahydrate (CCH) (ECE-CCH) by melting-solidification method and devised an electrically-controlled phase change material (PCM) preheating system based on CCH (EPS-CCH) for LIBs. The stable supercooling and great heat storage/release properties of the CCH, as well as the excellent low-voltage electrically-controlled crystallization performance of ECE-CCH, enable EPS-CCH to achieve safe and controllable thermal management of LIBs at the optimal operating temperature. Under the premise of maintaining the stable supercooling and heat storage properties of CCH (50.67 wt% CaCl 2 solution), 48 wt% CaCl 2 solution was selected as the heat storage material (melting point: 31.5 °C, latent heat: 153.0 J /g). The ECE-CCH could release the latent heat of the supercooled CCH solution in <5 s at low DC voltages (1.0–2.0 V). 100-cycle experiments illustrated that ECE-CCH had good cycle stability and an optimal operating voltage range of 1.0–1.5 V. Finally, EPS-CCH was designed to achieve on-demand control of thermal management of LIBs at low temperatures. Compared to LIBs without EPS-CCH at 5 °C, LIBs with EPS-CCH exhibited a significantly increased discharge capacity of 14.27%, 11.35%, and 7.04% at discharge rates of 0.5C, 1.0C, and 1.5C, respectively. The research findings of the ECE-CCH and the EPS-CCH would promote the development of LIBs preheating technologies. • A novel electrically-controlled electrode based on calcium chloride hexahydrate (CCH) was developed. • The crystallization of supercooled CCH was electrically triggered by 1.5 V DC voltage. • The crystallization behavior of supercooled CCH was investigated in-depth. • The EPS-CCH achieved a smart thermal management of lithium-ion batteries. [ABSTRACT FROM AUTHOR]

Efforts to mitigate environmental pollution from the use of petroleum-based energy sources have promoted research on rechargeable secondary batteries for applications such as electric vehicles and energy storage systems. In this context, Li-ion batteries have attracted significant interest. Notably, the thermal management of such batteries is crucial for achieving a stable output and long lifespan and reducing the risk of thermal runaway. Despite extensive exploration of various cooling schemes, thermal management techniques for Li-ion batteries continue to face challenges due to the high thermal resistance resulting from low thermal conductivity of thermal interfacial materials and inadequate convective heat transfer. Therefore, this study is aimed at using laser-induced graphene (LIG) to enhance the heat transfer characteristics and battery thermal management. LIG is applied through direct laser irradiation on the polyimide substrate of a LiFePO 4 battery. Thermal tests conducted under a discharge rate of 5C demonstrate that immersion cooling using HFE-7000 on the LIG surface substantially reduces the temperature increase by up to 84.3% compared with conventional air cooling. In addition, immersion cooling with LIG surfaces results in outstanding cooling performance through nucleate boiling, attaining a maximum temperature of 37.5 °C, which is lower than that (43.5 °C) on a pristine polyimide surface. Overall, this research provides valuable insights into the thermal management of high-performance batteries operating under extreme conditions, such as high-speed charging, high-power discharging, and high-temperature conditions, with significant implications for future applications. • Introducing laser-induced graphene (LIG) for novel immersion, boiling cooling. • Various aspects of battery behavior were investigated, including discharge rates, working fluids, and temperatures. • LIG-coated battery enhances thermal performance, especially in high-temperature and high C-rate conditions. • LIG-coated battery exhibited a remarkable temperature reduction of up to 84.3%. [ABSTRACT FROM AUTHOR]

The demand for high energy density in lithium-ion battery packs for electric vehicles poses a challenge to maintaining its optimum operating temperature while reducing the risk of thermal runaway (TR) propagation. This study proposes a novel hybrid TR propagation mitigation system that balances heat transfer and thermal insulation requirements using low and high thermal conductivity phase change materials (PCM), heat pipes (HP), and air-cooling. The design and optimization of such a mitigation system are complex due to the many design parameters involved. The Adaptive-Kriging-High dimensional model representation (Adaptive-Kriging-HDMR) is used to establish a surrogate model of the system, and the sensitivity of the system's design parameters is evaluated with the maximum battery temperature and the system weight as the targets, thereby improving the efficiency of model calculation and reducing the dimension of optimization parameters. Then, the design of the sensitive parameters is optimized using an extended elitist non‐dominated sorting genetic algorithm (E-NSGA-II) multi-objective optimization algorithm. The results show that the modeling difficulty and optimization calculation time are significantly reduced by using a surrogate model. The calculation time for a single surrogate model only takes a few seconds instead of several hours for the original three-dimensional heat transfer and flow calculation. The thermal conductivity of high thermal conductivity-PCM, the distance between battery and low thermal conductivity-PCM, the battery spacing, and the HP length significantly affect the system. The optimized system substantially reduces the overall weight of the battery system while ensuring its good heat dissipation capability. In the case of TR in a single battery, the system succeeds in limiting the TR propagation to the same row, with the maximum battery temperature in the second row being only 64.3 °C, well below the battery TR trigger point. Under more severe conditions, such as TR occurring in two batteries simultaneously, the maximum battery temperature in the second row is 155.5 °C, and no TR spreads to the adjacent row. This study provides a rapid and effective method for designing a TR propagation mitigation system. It can serve as a reference for the engineering design and optimization of battery thermal management systems. [ABSTRACT FROM AUTHOR]

This study introduces a streamlined modeling framework that integrates a volume-averaged thermal (VAT) model with the Tank-in-Series battery model, a recently developed volume-averaged electrochemical model. The framework enables efficient simulations of electrochemical-thermal interactions in large-scale battery packs. This framework is used to investigate the effects of coolant flow rates and inlet temperature, initial and ambient temperatures, battery pack configurations, and cell-to-cell manufacturing related variations. Results showed a notable current distribution variation among modules connected in parallel at the end of discharge and beginning of charge. This is found to be directly related to the temperature variation in the battery pack governed by the coolant mass flow rate. Additionally, with the introduction of a 0.5% cell-to-cell to variation in the cell design parameters for the purpose of simulating manufacturing variation, a significant voltage variation of over 0.2 V across cells is found to be possible. Furthermore, rapidly changing the inlet temperatures to simulate a potential battery management system failure indicated the risk of some cells in the pack exceeding the desired cut-off voltage. The present framework can be used to design battery packs with effective thermal management strategies, enhancing the overall reliability and performance of battery systems. • Developed a multiphysics modeling framework to simulate electrochemical-thermal characteristics of Li-ion battery packs • Flexible, scalable, and efficient physics-based simulation of Li-ion battery packs • In-depth analysis of Li-ion battery pack at various operating conditions, including extreme thermal conditions • Effect of cell-to-cell manufacturing variation on cell-level and pack-level electrochemical and thermal characteristics [ABSTRACT FROM AUTHOR]

• Developed and analyzed a novel hybrid battery pack thermal management system. • Incorporated a novel three-stage cooling strategy into the thermal management system. • Latent heat of PCM effectively extracts heat from the cylindrical Li-ion cells. • Secondary coolants increase the overall heat transfer coefficient of PCM. This paper introduces a novel hybrid thermal management concept, which use secondary coolants (air and water) to extract heat from a phase change material (paraffin), resulting in increased heat extraction capability of the paraffin and improvement the overall thermal performance of the battery module. This concept was analyzed using experimental and numerical studies. The experimental studies were conducted to obtain the temperature and heat flux profiles of the battery module. The numerical model is developed and validated using the experimental data obtained. The outcome of the study showed that the battery module temperature reached the phase change temperature threshold of the PCM in the fifth discharge cycle, and the through the use of latent heat the battery module temperature was maintained between 42 and 44 °C. Additionally, the thermal uniformity started to increase once the PCM started to change and the PCM utilization was ∼2.3 % after seven discharge cycles. Therefore, the proposed thermal management concept for the battery module can sustain the thermal environment needed for effective operation of the Lithium-ion batteries. [ABSTRACT FROM AUTHOR]

Lithium-ion batteries are the most commonly used battery type in commercial electric vehicles due to their high energy densities and ability to be repeatedly charged and discharged over many cycles. In order to maximize the efficiency of a li-ion battery pack, a stable temperature range between 15 °C to 35 °C must be maintained. As such, a reliable and robust battery thermal management system is needed to dissipate heat and regulate the li-ion battery pack's temperature. This paper reviews how heat is generated across a li-ion cell as well as the current research work being done on the four main battery thermal management types which include air-cooled, liquid-cooled, phase change material based and thermo-electric based systems. Additionally, the strengths and weaknesses of each battery thermal management type is reviewed in this study. It was determined that air cooled systems are suited for short-distance travel electric vehicles, liquid cooled are for electric vehicles that require long-distance travel, larger battery packs and for high thermal loads, phase change material based are for electric vehicles with constant thermal loads and stable ambient temperatures and thermo-electric battery thermal management systems are best best suited in conjunction with the other types for better control. • Present simplified heat generation model for li-Ion batteries. • Review of upcoming PCM Cooling BMS models. • Analysis of strengths and weaknesses of air, liquid, PCM, and thermoelectric BMS. • Recommendation on appropriate BTMS type for different EV models. • Identified main attributes required for an effective BMS for EV systems. [ABSTRACT FROM AUTHOR]

For cylindrical Li-ion battery packs, the battery thermal management system can be properly designed and analyzed from an energy-exergy viewpoint during charging and discharging to ensure the proper functionality of batteries; however, not been explored yet. Hence, cylindrical Li-ion battery pack with novel-designed serpentine microchannel-cooled thermal management system are analyzed. Applying the Multi-Scale Multi-Domain Newman, Tiedemann, Gu, and Kim model, an electrochemical model is used for the 3D battery thermal modeling. Effects of circular and rectangular cross-sectional shaped microchannels and using ternary hybrid nanofluids [THNF1 (Al 2 O 3 (0.5%) + Cu (0.5%) + MWCNT (1%)/water) and THNF2 (Al 2 O 3 (0.5%) + Cu (0.5%) + Graphene (1%)/water] are investigated at a 3C-discharge rate. Results indicate that the use of ternary hybrid nanofluid and microchannel cross-sectional shape has a strong influence. Maximum temperature, temperature uniformity, pumping power, heat transfer coefficient to pressure drop ratio, and entropy generation are the key factors. The present simulation can predict individual battery thermal behavior during charging and discharging. The suggested design successfully lowers the cell temperature to 305.24 K by using THNF2 and the temperature difference to 5.23 K of the 26,650-type cylindrical cell. Rectangular cross-sectioned microchannel is found to be more effective. The thermal control of batteries is greatly enhanced by using ternary hybrid nanofluid. The suggested technique will improve the battery life. • Novel serpentine microchannel-cooled system is proposed for cylindrical battery pack. • Multi-Scale Multi-Domain Newman, Tiedemann, Gu and Kim model is used for battery. • Different microchannel cross-sections and ternary hybrid nanofluids are investigated. • Thermal performance parameters, pressure drop and entropy generation are evaluated. • Suggested design and fluid successfully keep cell temperature within desired range. [ABSTRACT FROM AUTHOR]