Computational Simulation of Bioinspired Hybrid Cooling for EV Battery Systems

Cheok, Kai Xyan (2026) Computational Simulation of Bioinspired Hybrid Cooling for EV Battery Systems. Final Year Project (Bachelor), Tunku Abdul Rahman University of Management and Technology.

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Abstract

The rapid growth of electric vehicles (EVs) highlights the necessity for effective Battery Thermal Management Systems (BTMS) to ensure the safety, performance, and lifespan of lithium-ion batteries. Conventional cooling strategies such as air, liquid, and phase change material (PCM) have limitations such as low thermal conductivity, non-uniform cooling, and performance degradation at high charge/discharge rates. In order to improve heat transfer, temperature uniformity, and thermal stability, this study proposes a bioinspired hybrid BTMS that combines PCM with honeycomb-structured cooling channels. This research performs a numerical investigation into the thermal performance of a bioinspired honeycomb-structured hybrid BTMS using ANSYS Fluent. The study systematically evaluates the impact of geometric parameters, including hexagonal cell sizes (10 mm, 15 mm 20 mm), channel heights (2 mm to 3 mm), and port locations, to maintain a maximum temperature (Tmax) below 323K and a temperature difference (ΔT) under 5K. Results identified the 15 mm polygon geometry as the optimal configuration for balancing surface area and fluid resistance. Performance was further assessed under highintensity 4C and 5C discharge cycles across varying inlet velocities (0.01m/s to 0.05m/s) and flow configurations. Among the tested patterns, Flow 2 (Counter-flow across plates) emerged as the most energy-efficient operating point. At an inlet velocity of 0.03m/s, the system achieved an exceptional ΔT of 2.05K and a Tmax of 317.67K during 4C discharge, while maintaining the PCM liquid fraction within the targeted 0.6 to 0.8 range. This optimized bioinspired design demonstrates superior thermal stability compared to conventional straight-channel systems which 3.9K in ΔT, proving that strategic geometric manifolding and counter-flow arrangements can significantly extend battery life and safety in high-performance applications