Last Updated: 2026-04-10 | Author: ToneCooling Thermal Engineering Team
Thermal Performance Analysis of Liquid Cold Plate for 1P104S Battery Module
With the growing demand for thermal management in electric vehicles and energy storage systems, Tone Cooling has developed and produced an aluminum cold plate for 1P104S battery module to ensure battery safety and long-term performance.
The liquid-cooled system has been tested under various coolant flow rates, providing reliable data for optimal thermal management. High-voltage battery modules generate significant heat during charge and discharge. The Tone Cooling‘s liquid cold plate ensures uniform cell temperatures, prevents overheating, and enhances battery lifespan
Simulation Methodology
Geometric Model
- Module consists of 104 cells, connected in 1P52S configuration.
- Cooling method: bottom-mounted liquid cold plate.
Simulation Parameters
- Initial cell temperature: 25 °C
- Charge-discharge rate: 0.5P
Flow Rates Tested
-
8 L/min, 10 L/min, and 12 L/min
Key Simulation Results
12 L/min Coolant Flow
- Maximum cell temperature: 32.3 °C
- Maximum temperature difference between cells: 1.5 °C
- Cold plate flow resistance: 37.7 kPa
- Coolant inlet temperature: 26.7 °C
At 12 L/min, the module reaches thermal equilibrium during 0.5P charge-discharge. Temperature rise remains within acceptable limits, meeting design requirements.
Comparison with 8 L/min and 10 L/min
- Increasing flow rate improves heat dissipation and reduces temperature difference between cells.
- Flow resistance increases with higher flow rates, which may impact pump power requirements.
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