Optimized design of micro-channel cold plates for unmanned vessel energy storage batteries based on orthogonal experiments

This study addresses the thermal management challenges of energy storage batteries in amphibious unmanned surface vehicles under high power conditions through an innovative cross-flow micro-channel cold plate. The design incorporates dual inlets and outlets that create two independent, staggered fluid channels. Combined with a manifold-inspired distribution structure, this configuration significantly improves flow uniformity and cooling performance. An orthogonal experimental design was employed to examine the effects of coolant type, inlet temperature, and flow velocity on the thermal-hydraulic performance. The CFD simulations verified that the optimal parameter combination, which uses liquid water at 26°C and a flow velocity of 0.5 m/s, allows the cold plate to maintain the surface temperature of a 1200 W heat source at 27.88℃, with a pressure drop of only 3.76 kPa. This design achieves an effective balance between high heat dissipation and low pumping power consumption, demonstrating its strong potential for thermal management in high energy density battery systems.