30-cell pouch-cell battery module architecture, busbar integration, liquid-cooled baseplate design and coupled electro-thermal-fluid simulation.
Representative 30-cell pouch-cell battery module with busbar connections and liquid-cooled baseplate architecture.
Overview
This case study presents battery pack design and coupled electro-thermal-fluid simulation work for a representative 30-cell pouch-cell battery module. The work combined module architecture, busbar and conductive path definition, liquid-cooled baseplate design, serpentine cooling-channel integration and transient multiphysics simulation using open-source engineering tools.
Engineering Challenge
Battery module development requires mechanical layout, electrical interconnection, thermal path design and cooling architecture to be considered together. The module needed a realistic engineering representation of pouch cells, conductive busbars, heat generation, thermal spreading through the cell stack and active liquid cooling through a compact cold-plate/baseplate arrangement.
Engineering Approach
– Developed a representative 30-cell pouch-cell battery module architecture.
– Defined cell layout, busbar/interconnect geometry and conductive current paths.
– Integrated a liquid-cooled serpentine baseplate/cold-plate concept into the module architecture.
– Combined battery cells, busbars, conductive paths, thermal interfaces and cooling geometry into one simulation model.
– Implemented coupled electro-thermal behaviour with temperature-dependent electrical losses.
– Used Gmsh, Elmer FEM, ParaView and Python-based preprocessing/post-processing workflows.
Battery Pack Architecture and Cooling Design
The model was developed as a battery pack/module design study rather than a simple thermal block. The architecture included a 30-cell pouch-cell arrangement, conductive busbar connections, a baseplate/cold plate and an internal serpentine liquid-cooling channel. This allowed the thermal response of the mechanical and cooling architecture to be assessed together with the electrical loss distribution.
Coupled Electro-Thermal-Fluid Model
The workflow included electro-thermal coupling through Joule heating generation with temperature-dependent DC internal resistance (DCIR), transient thermal conduction through the module, fluid flow in the cooling circuit and conjugate heat transfer between the cooling system and battery structure.
Coupled Loss Behaviour
During the 120 s transient, Joule heating power increased from approximately 1.88 kW to 2.18 kW as the temperature-dependent electrical behaviour changed with temperature. This demonstrates the coupled nature of the model, where electrical losses are updated as the thermal field evolves.
Numerical Workflow
The geometry and meshing workflow was developed using Gmsh, while Elmer FEM was used to solve the coupled thermal, electrical and fluid-flow equations. ParaView and Python were used for result visualisation and post-processing. The final coupled transient simulation required approximately 12.5 hours of computational time.
Engineering Relevance
The work demonstrates capability in battery pack/module architecture, thermal management, electro-thermal simulation, cooling-system evaluation and multiphysics workflows applicable to EV battery systems, energy storage systems and thermal architecture optimisation.
Simulation Results and Visualisation
Elevated thermal loading case showing progressive heating across the module.
Side view thermal gradient distribution through the battery cells and baseplate.
Serpentine cooling channel integrated within the liquid-cooled baseplate.
Flow and thermal visualisation within the cooling architecture.
Transient temperature evolution and module thermal response over simulation time.
Final coupled thermal-fluid solution with active liquid cooling.
Current vector field visualisation showing electrical current distribution through the module and busbar connections.
Transient temperature evolution over the 120 s simulation period.
Outcome
– Developed a battery pack/module design and simulation workflow for a representative 30-cell pouch-cell architecture.
– Integrated cell layout, busbar/current paths, liquid-cooled baseplate design and thermal interfaces within one engineering model.
– Demonstrated coupled electrical loss generation, transient thermal conduction and active liquid cooling in a single workflow.
– Generated design-relevant thermal, flow and current-distribution outputs for battery thermal-management assessment.
– Established a reusable foundation for future battery pack design studies, parameterised modelling and web-based simulation workflows.
Future Development Direction
This work forms the foundation for future development of parameterised battery pack simulation workflows, automated geometry generation, cloud-executed thermal studies and future web-based engineering simulation applications.
Confidentiality Note
This case study is based on representative battery pack design and simulation work. No confidential customer geometry, proprietary product design data, internal client specifications or restricted project documentation are disclosed.