The electrochemical performance and operational lifespan of lithium-ion batteries deteriorate significantly at low temperatures, resulting in reduced discharge capacity and extended charging times. Therefore, a novel approach by integrating a topology-optimized heat exchange plate and fluid dynamics analysis is proposed to enhance heating efficiency, which is evaluated by comparing the minimum time required to heat the battery pack under different fluid flow rates, fluid temperatures, and battery spacing conditions. Results demonstrate that the topology-optimized preheating system exhibits significant potential for improving both heating performance and battery safety. It achieves a 25% improvement in heating efficiency and a 36% reduction in pressure drop, with the pressure drop reduced to 13.1 Pa. Furthermore, an orthogonal experimental design is employed to identify the optimal preheating strategy, balancing operational performance and energy efficiency. The system delivers superior performance and temperature uniformity at Vin = 0.20 m/s and Tin = 313.15 K, where it achieves the minimum heating time of 395 s and the maximum temperature difference of 3.86 K within the battery pack. It provides a viable solution for rapid preheating of electric vehicle batteries operating in low-temperature environments.
Yao et al. (Wed,) studied this question.