What is it about?
Lithium-ion batteries power many devices, but keeping them cool is a challenge. Uneven temperatures in battery packs can reduce performance, shorten lifespan, and even cause overheating. Our research introduces an "aero-fin" design around each battery cell to improve cooling. This design enhances airflow and heat dissipation, preventing the typical rise in temperature seen in conventional air-cooled packs. We tested different aero-fin setups and found one that keeps temperatures more uniform and reduces airflow resistance. This approach can make lithium-ion batteries safer and more efficient, helping them last longer.
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Why is it important?
Efficient thermal management is vital for lithium-ion batteries used in electric vehicles (EVs). When batteries overheat, their performance, safety, and lifespan are significantly reduced, and in extreme cases, this can lead to thermal runaway or fire hazards. Air cooling is the simplest and most cost-effective method, but its performance is often insufficient for high-power applications. This study introduces a new aero-fin design that improves air circulation and heat removal from each battery cell. By shaping the fins like airfoils, the system increases the cooling efficiency without adding extra weight or complex components. The research identifies an optimal aero-fin angle that keeps all battery cells within safe temperature limits while minimizing pressure loss. These findings are crucial for developing safer, lighter, and more energy-efficient battery packs, directly contributing to the reliability and sustainability of electric vehicles.
Perspectives
The proposed aero-fin battery cooling concept offers a new direction for advancing air-cooled battery thermal management systems (BTMS). Traditional air-cooling methods often struggle to maintain uniform temperatures across battery cells, limiting their use to low-power applications. The introduction of aero-fins with controlled inclination angles enhances both convective heat transfer and airflow uniformity, addressing this critical limitation. From a broader perspective, this research demonstrates that geometrical flow manipulation—rather than relying solely on external cooling power or complex liquid systems—can substantially improve thermal control. The design can be scaled and optimized for various battery pack geometries and discharge rates, paving the way toward lightweight, low-energy, and cost-effective cooling solutions for next-generation electric vehicles and energy storage systems. Future work could integrate multi-objective optimization and experimental validation to refine the aero-fin geometry for real-world implementation, potentially leading to commercially viable BTMS designs that balance safety, efficiency, and manufacturability.
Sutheesh P M
National Institute of Electronics and Information Technology - Calicut
Read the Original
This page is a summary of: Thermal Management of Lithium-Ion Battery with Novel Aero-Fins: A Numerical Study, Journal of Thermophysics and Heat Transfer, April 2025, American Institute of Aeronautics and Astronautics (AIAA),
DOI: 10.2514/1.t7155.
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