Summary
The performance, lifetime, and safety of electric vehicles (EVs) are highly reliant on the battery's capacity and temperature. Battery thermal management system (BTMS) involves techniques to control the battery's thermal behavior by maintaining temperature and temperature uniformity within an optimal range. Air cooling BTMS is frequently used in EVs due to its design simplicity and cost‐effectiveness. Only limited works have utilized passive convective heat transfer enhancement strategies for air‐cooled BTMS, especially fin‐based structures for cylindrical lithium‐ion battery packs. Present work introduces a novel design by incorporating the interrupted fins into a conventionally air‐cooled BTMS. The proposed design offers superior heat transfer efficiency as well as ease of manufacturing when compared to the existent herringbone fin design used in prior air‐cooled BTMS literature. Results indicate that the average temperature of the cells and maximum temperature difference were reduced by 5.646 and 7.958 K, respectively, by incorporating an optimal uniform interrupted fin arrangement. The average temperature of the cells was reduced by 0.479 K when the interrupted fins were added to increase the area, compared to 0.088 K for an equivalent area enhancement in a conventional fin. The uniform interrupted fin improved the temperature uniformity by 5.05%, but the area enhanced conventional fin deteriorated it by 1.59%. The non‐uniform interrupted fin arrangement, resulted in an improvement of 4.47%, over uniform interrupted fins, in the battery pack's temperature uniformity.