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• Develops a lightweight liquid cooling solution to cool a prismatic hard cased cell. • Effect of fluid flowing on cell thermal distribution is studied numerically. • Dimensionless analysis of cooling performance in cooling plate is performed. • Effectiveness of the lightweight solution was authenticated by an experimental test. The lightweight thermal design is a critical factor that must be taken into consideration during the lithium-ion battery pack manufacturing for electric vehicles. This work develops a lightweight liquid cooling solution to cool a prismatic hard-cased cell from its small lateral surfaces. The effects of fluid flow directions, flow rates, channel dimensions, and cooling mediums on the cell′s thermal distribution were studied. Meanwhile, a dimensionless analysis for the cooling plate performance was imposed. The simulation effectiveness was corroborated through experiments. Simulations show that the lightweight thermal design has a similar cooling effect with the conventional thermal design; crucially, the former can lower the cooling plate weight by 57% compared with the later. Effect of increasing fluid flow rate on minimizing the cell′s temperature rise and difference is positive and negative, respectively. Increasing fluid flow rate and channel width can promote the cooling plate performance. The glycol aqueous solution outperforms the liquid water to weaken the cell′s temperature difference. Experiments authenticating that an excellent effectiveness residing in the current lightweight thermal design to control the cell thermal profile within a desirable level. This work would be valuable for one to design a lightweight cooling system for a battery pack consists of prismatic hard-cased cells. [ABSTRACT FROM AUTHOR]

Purposing to the thermal profile management of typical format 21700 lithium-ion battery cells, this study develops a cellular liquid cooling jacket to meet their requirements. To this end, the effects of fluid flowing, channel dimension, and cooling medium on the cell thermal profile were investigated numerically, and then the simulation effectiveness was authenticated experimentally as per a constructed test bench. Meanwhile, a non-dimensional analysis for the optimum design of cellular cooling jacket was implemented. The results show that the interlaced flow directions can capture a lower temperature standard deviation and a more even thermal distribution. The non-dimensional analysis reveals that the increasing fluid flow rate and channel size can effectively promote the performance of high-efficiency and low-impedance in the designed cellular cooling plate. The glycol aqueous solution to minimize cell's temperature difference and temperature standard deviation is under a stronger capability than that of the liquid water. Experimental verification indicates that the developed cellular cooling jacket is of great control effectiveness to the thermal profile of the cylindrical 21700 cells. A benefit inside this study for the thermal management system designing for the power battery pack of composing with the cylindrical 21700 cells. • A cellular cooling jacket is developed to control thermal profile of a 21700 cell. • Impact of fluid flowing on 21700 cell thermal profiles is studied numerically. • Dimensionless analysis of the cellular cooling jacket performance is conducted. • The effectiveness of battery pack thermal design is verified by a built test bench. • The thermal design is of great effectiveness to control 21700 cell thermal field. [ABSTRACT FROM AUTHOR]