This research introduces a novel hybrid pin-blade fin architecture for lithium-ion battery thermal management systems, strategically integrating complementary fin geometries to overcome the traditional thermal-hydraulic performance trade-off. Through comprehensive 3D CFD simulations, the hybrid design achieves remarkable dual improvement: maintaining battery temperatures below 21.5°C during 5C discharge (1°C lower than conventional designs) while reducing pressure drop by 30% compared to equivalent pin-fin configurations. The investigation reveals that smaller pin diameters (2.5mm) provide superior thermal performance, while higher blade angles (80°) significantly reduce hydraulic resistance. By combining these optimal features, the hybrid architecture delivers exceptional cooling efficiency while requiring 7% less aluminum and 66% less coolant than benchmark designs. Quantitative analysis shows that reducing pin diameters from 10mm to 2.5mm decreases maximum battery temperature by 0.3°C, while optimizing blade orientation angles can reduce pressure drop by up to 65 Pa at 0.2 L/min flow rate. The innovative cooling plate achieves rapid thermal stabilization within 150 seconds and sustains temperature uniformity across the battery surface. This breakthrough approach resolves the long-standing dilemma between thermal regulation and hydraulic penalties in battery cooling systems, establishing a new standard for high-performance, material-efficient thermal management in electric vehicle applications.
Jalalichaleshtori, S. and sheikhzadeh, G. (2025). Cooling Performance Enhancing by Employing Hybrid Pin-Blade Fin Geometry with Constant Weight for Prismatic Lithium-Ion Batteries. Journal of Heat and Mass Transfer Research, (), -. doi: 10.22075/jhmtr.2025.36024.1645
MLA
Jalalichaleshtori, S. , and sheikhzadeh, G. . "Cooling Performance Enhancing by Employing Hybrid Pin-Blade Fin Geometry with Constant Weight for Prismatic Lithium-Ion Batteries", Journal of Heat and Mass Transfer Research, , , 2025, -. doi: 10.22075/jhmtr.2025.36024.1645
HARVARD
Jalalichaleshtori, S., sheikhzadeh, G. (2025). 'Cooling Performance Enhancing by Employing Hybrid Pin-Blade Fin Geometry with Constant Weight for Prismatic Lithium-Ion Batteries', Journal of Heat and Mass Transfer Research, (), pp. -. doi: 10.22075/jhmtr.2025.36024.1645
CHICAGO
S. Jalalichaleshtori and G. sheikhzadeh, "Cooling Performance Enhancing by Employing Hybrid Pin-Blade Fin Geometry with Constant Weight for Prismatic Lithium-Ion Batteries," Journal of Heat and Mass Transfer Research, (2025): -, doi: 10.22075/jhmtr.2025.36024.1645
VANCOUVER
Jalalichaleshtori, S., sheikhzadeh, G. Cooling Performance Enhancing by Employing Hybrid Pin-Blade Fin Geometry with Constant Weight for Prismatic Lithium-Ion Batteries. Journal of Heat and Mass Transfer Research, 2025; (): -. doi: 10.22075/jhmtr.2025.36024.1645
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