As electric vehicles (EVs) continue to gain global market share, the thermal management of lithium-ion battery packs has emerged as a critical challenge affecting performance, safety, and longevity. Conventional air-cooling and coarse liquid-cooling systems struggle to maintain optimal temperature uniformity and dissipate high heat fluxes during fast charging and high-power discharge cycles. This report investigates a passive microfluidic approach based on Tesla‑valve (valvular conduit) microchannels to rectify oscillatory or disturbed flow and enhance thermal uniformity without moving parts. Building on recent studies that integrate Tesla‑type channels into battery cold plates and hybrid battery thermal management systems (BTMS) with phase‑change materials, we outline a geometry and operating‑regime rationale for high diodicity with acceptable pressure drop. Representative simulations and published data indicate that Tesla‑valve cold plates can reduce peak cell temperatures and temperature spread (ΔT) while maintaining comparable or lower pumping power than serpentine baselines at relevant Reynolds numbers, thereby reducing exergy destruction and improving system efficiency. The proposed methodology, optimization guidelines, and fabrication routes consolidate a path to practical EV cooling plates where passive rectification stabilizes flow distribution under real-world transients
Microfluidic Thermal Management for Battery Cooling: A Review on Tesla-Valve Microchannel Approach to Solve Flow Maldistribution and Thermal Non-Uniformity
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