Pseudo three-dimensional topology optimization of cold plates for electric vehicle power packs.

• The pseudo 3D topology optimization approach for cold plate design was introduced. • Penalty coefficients, objective function weights, and re substantially influenced the results of topology optimization. • Temperature variance constraints greatly enhanced topology optimized cold plate temperature uniformity. • Topology optimized cold plate showed excellent heat dissipation and temperature uniformity. • Topology optimized cold plates outperformed parallel flow channel cold plates in cooling performance. This study develops a liquid-cooled cold plate for battery packs in electric vehicles using pseudo three-dimensional topology optimization techniques. The objective of optimization is to reduce both temperature and energy consumption of flow, while simultaneously enhancing the temperature uniformity of the structure by using temperature variance as a constraint in the topology optimization procedure. An analysis was conducted to establish the structure of the cold plate by examining the impacts of topological optimization penalty coefficients, Reynolds number, objective function weights, and temperature variance limitations on the optimization outcomes. Ultimately, the numerical simulation assesses the thermal efficiency and flow properties of the topology optimized cold plate within a battery pack. It demonstrates superior heat dissipation and temperature uniformity when compared to the Parallel-channel cold plate. With a mass flow rate of 0.0052 kg/s, the battery equipped with topology optimized cold plate has an average temperature of 302.9 K, a maximum temperature of 304.25 K, and an internal temperature difference of 4.7 K. The average temperature is 1.18 K lower and the maximum temperature is 1.8 K lower compared to the battery with Parallel-channel cold plate. This study offers a highly effective resolution to the issue of cold plate design for battery heat dissipation. [ABSTRACT FROM AUTHOR]