Effect of Aerodynamically Induced Passive Airflow Cooling on Various Configurations of Lithium‐Ion Battery Pack for Electric Vehicles: A Numerical Case Study

ABSTRACT

Lithium‐ion batteries (LIBs) are widely used in electric vehicles due to their high energy density, strong electrochemical performance, and long cycle life. However, their safety and efficiency are highly affected by heat generation during charge–discharge operations. This study investigates a passive airflow‐based cooling strategy driven by aerodynamic‐induced airflow over front‐mounted battery cells. Initially, two configurations, such as in‐line cell arrangement (ILCA) model and staggered cell arrangement (SCA) model. Later, a modified battery cell arrangement, assigned a simplified designation to improve clarity and consistency in the comparative analysis, is analyzed to evaluate thermal performance under varying inlet airflow velocities. Simulations were conducted for airflow velocities ranging from 0 to 20 m s ⁻¹ . Under natural convection (0 m s ⁻¹ ), the maximum battery temperature reached 352.52 K (79.52°C). Introducing airflow at 10 m s ⁻¹ reduced the temperature to 303.52 K (30.52°C), achieving a significant 49°C reduction. Results indicate that increasing airflow velocity progressively enhances heat dissipation. The maximum temperature difference within the battery pack remains within ⁓5°C, ensuring uniform and safe operation. All configurations demonstrate effective thermal management. Among the investigated configurations, the ILCA provided comparable thermal performance while accommodating more cells within the same battery pack volume.