New energy vehicles (NEVs) have become the future direction of the automotive industry due to their environmental benefits and energy efficiency. The power battery provides the necessary energy for electric vehicle operation, and its performance plays a critical role in determining the vehicle's power efficiency, lifespan, and stability.
During vehicle operation, the battery generates a significant amount of heat. If this heat accumulates within the battery pack, it causes an increase in battery temperature. When the battery's maximum temperature exceeds its optimal operating range, its performance degrades, and in severe cases, it may lead to fire or explosion. Therefore, effective thermal management is essential to maintain battery temperatures within a safe and efficient range.
This study, conducted in collaboration with an industrial project, focuses on the cooling plate of a new energy passenger vehicle battery. A three-dimensional software model was developed to simulate battery heat generation, and experimental validation was conducted. Furthermore, thermal topology optimization was applied to refine the initial cooling plate channel layout. Finally, the optimized cooling plate was analyzed for thermal characteristics, evaluating the impact of various factors on its cooling performance.

Key Research Work:
Battery Heat Generation Modeling
The structural, heat generation, and heat transfer principles of the target vehicle’s power battery were analyzed, leading to the development of a battery heat generation model.
Discharge experiments and simulations were conducted under different discharge rates. A comparison between simulation results and experimental data showed an error of less than 5%, confirming the model's accuracy.

Initial Cooling Plate Performance Evaluation
Simulations were conducted on the battery module and initial cooling plate under different discharge rates to determine cooling performance parameters.
Without a cooling plate, the battery’s maximum temperature exceeded its optimal operating range. After adding the cooling plate, the battery temperature was successfully reduced to within its optimal range.
However, at 2C discharge, the temperature difference within the battery module exceeded the allowable 5°C limit, indicating a need for optimization of the cooling plate's channel layout.

Cooling Plate Structural Optimization
Traditional cooling plate designs rely on engineers' experience rather than theoretical foundations. To improve design efficiency, a topology optimization analysis was conducted.
Using the variable density method, two optimized heat dissipation structures were designed for uniformly heated regions, providing a theoretical basis for further cooling plate design improvements.
Final Cooling Plate Optimization and Performance Analysis

The initial cooling plate was optimized based on the topology optimization results.
Simulation analyses were conducted on the optimized cooling plate, evaluating the effects of ambient temperature, coolant temperature, and coolant flow rate on its performance.

Results showed significant performance improvements:
The maximum battery temperature was reduced.
Temperature uniformity improved, ensuring the battery remained within its optimal operating range.
This study demonstrates that topology-optimized cooling plates can effectively enhance battery thermal management, ensuring better performance, safety, and longevity for new energy vehicle power batteries.