Design optimization methodologies applied to battery thermal management systems: A review

Heat generation during lithium-ion battery charge and discharge requires the implementation of battery thermal management systems (BTMSs) for enhanced battery performance, safety, and lifetime. Numerous design optimization methodologies have been recently implemented to improve BTMS cooling and heating performance, energy usage, efficiency, and mass. This paper provides a comprehensive and exhaustive review of BTMS studies that apply design optimization methodologies, categorizing them into surrogate-model-based, multi-objective, multidisciplinary, single objective, and design of experiments methodologies. This review paper also summarizes and discusses critical knowledge gaps, current trends, and opportunities in BTMS design optimization. Most of the literature applies multi-objective optimization methodologies with genetic algorithms, optimizing the design of structural BTMS components to minimize maximum battery temperature and spatial temperature gradients. This review paper also identifies opportunities for future applications of BTMS design optimization methodologies, including opportunities for performance improvements of hybrid BTMSs, battery lifetime, electric vehicle range, and heating strategies for battery pre-conditioning.