Search Results (184)

Battery thermal management systems (BTMSs) are essential for maintaining the performance, efficiency, durability, and safety of electric-vehicle battery packs. Although fin-enhanced air-cooled BTMSs offer a simple and leakage-free cooling solution, their practical implementation is often limited by increased weight, insufficient temperature uniformity, and restricted heat-dissipation capability under high thermal loads. This study numerically investigates a compact air-cooled BTMS for two types of cylindrical lithium-ion batteries using aluminum and polypropylene (PP-$\beta$) circumferential fins in inline and staggered cell arrangements. Unlike previous fin-based air-cooling investigations, the present study combines a compact 2 × 4 battery pack with transverse and longitudinal center-to-center cell pitches of 1.2D, a direct comparison between metallic and lightweight polymer fins, and an assessment of two 18650 battery types with different capacities, thermophysical properties, and heat-generation characteristics. A three-dimensional steady-state conjugate heat-transfer model was developed in ANSYS Fluent to evaluate the effects of fin number, fin material, cell arrangement, ambient temperature, and inlet airflow velocity under discharge rates ranging from 1 C to 4 C. The results reveal that increasing the number of fins consistently reduced the maximum cell temperature but increased the pressure drop. The inline configuration generally achieved a lower maximum temperature and higher Nusselt number (Nu), whereas the staggered arrangement maintained a substantially lower pressure drop. Relative to the corresponding finless configurations, the Nu increased by 64.4–71.2% for the inline arrangement and 86.4–98.1% for the staggered arrangement. Polypropylene fins provided thermal performance close to that of aluminum fins in terms of maximum temperature while reducing the total fin mass by approximately 44.8%; however, aluminum fins maintained better temperature uniformity. These findings quantify the trade-offs among thermal performance, pressure drop, compact cell spacing, and system weight, providing design guidance for compact fin-enhanced air-cooled BTMSs. Full article

With the rapid expansion of the global lithium-battery industry, efficient and sustainable lithium recovery from low-grade lithium resources, such as lithium precipitation mother liquor characterized by a high sodium-to-lithium ratio, has become a critical research challenge. Among the emerging technologies, the adsorption method, recognized for its operational simplicity, high selectivity, and process flexibility, has garnered significant attention. This review systematically summarizes recent advancements in two primary categories of adsorbents for selective lithium recovery: organic adsorbents (crown ether-based materials) and inorganic adsorbents (aluminum-based layered double hydroxides (LiAl-LDHs), titanium-based ion sieves (H₂TiO₃, H₄Ti₅O₁₂), and manganese-based ion sieves (HMn₂O₄, H₁.₆Mn₁.₆O₄, H₄Mn₅O₁₂). For each class, the synthesis methods, adsorption mechanisms, performance (capacity, selectivity, kinetics, and cycling stability), and key influencing factors are thoroughly discussed and compared. Titanium-based sieves demonstrate high capacity and stability, manganese-based materials show excellent kinetics, aluminum-based adsorbents offer industrial scalability, and crown ether-based materials exhibit superior ion size selectivity. The review also identifies limitations, such as the slow kinetics of H₂TiO₃, manganese dissolution in manganese-based ion sieves, and the cost of functionalized organics. Finally, future research directions are proposed, focusing on enhancing adsorption kinetics and stability via material design (e.g., morphology control, doping, hybridization), developing scalable and cost-effective synthesis routes, and exploring the integration of adsorption with other separation technologies to create efficient hybrid processes for the sustainable exploitation of low-grade lithium. Full article

With the increasing prevalence of lithium–ion batteries, the recycling of battery materials is becoming increasingly important. Functional recycling represents a promising approach in this context, one that is often based on aqueous treatment steps. This study examines the aqueous treatment of positive electrodes coated with various cathode active materials and their mixtures. To this end, the electrodes were leached in two different broad-range buffer systems in the pH range of 5 to 11. The investigations focused on the temporal evolution of the pH value, the time-dependent leaching of the active material components, and the dissolution of the aluminum current collector. The results show that process parameters, particularly the initial pH value, the treatment duration, and the composition of the process medium, influence both the leaching of the active materials and the corrosion of the aluminum current collector. Furthermore, the coated electrodes studied show significant differences in the stability of the active materials, which sometimes deviate from the properties of the respective pure active materials described in the literature, suggesting additional interactions within the electrode structure. The results highlight the need for targeted process optimization to create the conditions for the successful functional recycling of active materials from lithium–ion batteries. Full article

In this study, a liquid-cooled Battery Thermal Management System (BTMS) incorporating aluminum heat-conducting blocks was numerically investigated to enhance the thermal performance of lithium-ion battery modules used in electric vehicles. The proposed system was designed for a battery module consisting of cylindrical lithium-ion cells, and the effects of different geometric configurations on thermal behavior were analyzed using the Computational Fluid Dynamics (CFD) method. To efficiently evaluate the multi-parameter design space with reduced computational cost, a Taguchi L9 orthogonal experimental design was employed. The cooling channel configuration, aluminum heat-conducting block height, and battery pack geometry were considered as the primary design variables. The performance of each design configuration was assessed based on maximum temperature (T_max) and temperature uniformity (ΔT). Furthermore, an Analysis of Variance (ANOVA) was conducted to quantify the influence of the design parameters on the thermal performance of the system. The results revealed that the configuration comprising eight cooling channels, a 65 mm aluminum block height, and a 1 + 8 cylindrical battery arrangement exhibited the best thermal performance, achieving a maximum temperature of 303.45 K and a temperature difference of 1.25 K. The optimal design configuration provided a more uniform temperature distribution within the battery module, thereby enhancing thermal safety and operational reliability. Overall, the integration of CFD and the Taguchi method offers a systematic and efficient optimization framework for BTMS design, enabling effective evaluation of design alternatives with a reduced number of simulations and shorter computational time. Full article

The rapid growth of electric mobility, renewable-energy storage, and portable electronics has sharply increased global lithium demand. Conventional lithium extraction methods, including hard-rock mining and brine evaporation, are land-intensive, slow, water-consumptive, and carbon-intensive. Adsorption has therefore received substantial attention for lithium recovery, due to its simple operation, cost-effectiveness, and facile scalability. In this regard, zeolite-based adsorbents have emerged as promising next-generation materials, mainly because of their crystalline frameworks, tunable pore architectures, ion-exchange functionality, and exceptional thermal and chemical stability. Existing reviews on adsorption-based lithium recovery have predominantly focused on polymeric materials, ion-exchange resins, and lithium-ion sieves (including lithium manganese oxide-based, titanium-based, and aluminum hydroxide-based adsorbents). To fill this gap, we present a dedicated and comprehensive review of zeolite-based adsorbents for sustainable lithium recovery from non-conventional lithium resources such as brines, geothermal fluids, seawaters, and battery-recycling leachates. By systematically and rigorously analyzing existing studies on this topic, we identify five guiding design principles: (i) zeolite framework charge density, (ii) zeolite framework topology and pore architecture (iii) morphology (size and shape), (iv) zeolite-based hybrid materials, and (v) operational design parameters (e.g., pH and temperature). Each design element is discussed in depth to clarify how lithium adsorption capacity and selectivity, transport behavior, and adsorption mechanisms can be controlled across diverse feedstocks. We further discuss the advantages, limitations, and future research needs for zeolite-based lithium capture. To the best of our knowledge, this is the first review centered on zeolite-based materials for lithium recovery. The knowledge and insights provided here aim to drive researchers into advancing zeolite-based adsorbents toward sustainable, next-generation lithium recovery technologies. Full article

Silicon suboxide (SiO_x) has been extensively investigated as an anode material for lithium-ion batteries. However, its low electrical conductivity and significant volume expansion during cycling have hindered its practical application. Although compounding SiO_x with carbon can effectively alleviate these issues, practical challenges such as complex preparation processes and high production costs still remain. In this study, porous SiO_x/C anode materials were synthesized in a single step using residue after acid-extraction aluminum from coal fly ash (high silica slag) as the silicon source and calcium carbide as both the reducing agent and carbon source, in a NaCl-CaCl₂ molten salt medium. The intimate interface between SiO_x and carbon not only enhances the electrical conductivity of the electrode but also buffers volume expansion, while the porous structure inside the SiO_x/C particles facilitates rapid ion transport. The SiO_x/C anode fabricated from this material exhibits excellent electrochemical performance and cycling stability: the anode material synthesized at 700 °C for 3 h (denoted as SiO_x/C-700-3) retains a reversible specific capacity of 1093.58 mAh g⁻¹ after 1000 cycles at a current density of 0.4 A g⁻¹. Moreover, the optimized SiO_x/C-700-3 electrode achieves robust long-cycle stability under a high current density of 2 A g⁻¹, sustaining a reversible capacity of 486.22 mAh g⁻¹ after 800 cycles with an average Coulombic efficiency approaching 99.6%. The method proposed in this work provides a new strategy for the preparation of SiO_x/C anode materials and holds great significance for the high-value comprehensive utilization of coal fly ash and the protection of the ecological environment. Full article

This study presents a novel and accessible method for determining the specific heat capacity of cylindrical lithium-ion batteries without the need for specialized equipment for cell disassembly, climatic chambers, or expensive calorimeters. The proposed approach does not require disassembly of the cell. Since specific heat capacity is a key parameter in thermal modeling and is often unavailable in manufacturer datasheets, the method addresses an important practical gap. The measurement principle is based on recording the change in surface temperature caused by a short 30 s discharge pulse of 9 A. A thermographic camera captures infrared images at fixed time intervals, while an electromechanical module rotates the battery around its longitudinal axis, providing an accurate estimation of the average surface temperature during and after the pulse. The resulting temperature–time profiles are used to evaluate heat losses and compute the specific heat capacity. To validate the methodology, experiments were conducted on an aluminum cylinder of identical dimensions to an 18650 cell, made of Al 6082-T6 (Cp ≈ 896 J·kg⁻¹·K⁻¹). The results show a maximum deviation of 2.68% from the reference value, confirming the reliability of the proposed method for determining the specific heat capacity of cylindrical Li-ion batteries. Full article

Rising demand for high-performance battery thermal management systems (BTMSs) has rendered single-mode cooling insufficient for advanced lithium-ion batteries (LIBs) in new energy vehicles (NEVs), particularly under high discharge rates. This study proposes a synergistic hybrid BTMS integrating composite phase-change material (CPCM)–aluminum foam with liquid cooling to enhance thermal regulation of cylindrical battery modules under 5 C discharge conditions. Multiple liquid-cooled plate (LCP) configurations, including serpentine, straight, and leaf-shaped designs, together with different flow channel topologies (FCTs), were systematically investigated and optimized. The effects of coolant flow speed (CFS) and ambient temperature were also analyzed. Results indicate that the optimized leaf-shaped LCP with FCT #2 delivers superior performance, limiting the maximum temperature to 309.98 K, reducing temperature difference by 7.6%, and decreasing pressure drop by 88.79% compared to the serpentine configuration. Increasing CFS improves heat dissipation and delays PCM melting, although it raises pressure losses. Furthermore, the proposed system maintains a cell-to-cell temperature difference below 0.51 K, indicating excellent thermal uniformity. Compared to a CPCM-only system, the hybrid BTMS reduces peak temperature by 8.81 K under elevated ambient conditions (309.15 K), demonstrating strong potential for reliable and efficient thermal management in demanding operating environments. Full article

Liquid electrolytes in conventional lithium-ion batteries pose safety risks associated with flammability, leakage, and explosion, whereas solid polymer electrolytes are generally limited by insufficient ionic conductivity at ambient temperature, restricting the development of high-energy lithium batteries. To address these issues, flexible poly (vinylidene fluoride-co-hexafluoropropylene) (PVDF-HFP)-based gel polymer electrolyte membranes (GPEs) were prepared via a slit-coating process combined with UV curing. NASICON-type lithium aluminum titanium phosphate (Li_1.3Al_0.3Ti_1.7P₃O₁₂, LATP) and garnet-type tantalum-doped lithium lanthanum zirconate (Li_6.4La₃Zr_1.4Ta_0.6O₁₂, LLZTO) were introduced as inorganic ceramic fillers to improve the ion-transport and interfacial properties of the GPE. Among the investigated samples, the PVDF-HFP-based GPE containing 10 wt% LLZTO exhibited the best overall performance, with an ionic conductivity of 3.40 × 10⁻⁴ S·cm⁻¹ at ambient temperature and a Li⁺ transference number of 0.77. Cyclic voltammetry results showed that the LLZTO-modified electrolyte membrane exhibited sharper and more symmetric redox peaks, higher peak current response, and better curve overlap during repeated cycles, indicating improved electrochemical reversibility and interfacial stability. In addition, LLZTO incorporation enhanced the mechanical strength, broadened the electrochemical stability window, and improved the flame-retardant behavior of the membrane. The LiFePO₄/GPE/Li cell assembled with the optimized membrane delivered an initial discharge capacity of 160 mAh·g⁻¹ at 0.1 C and maintained 80 mAh·g⁻¹ at 1 C, demonstrating good rate capability. Moreover, a capacity retention of 96% was maintained after 100 cycles at 0.1 C, confirming excellent cycling stability. Therefore, this work provides an effective strategy for the structural optimization and scalable preparation of high-performance gel polymer electrolyte membranes for lithium battery applications. Full article

Electric vehicles (EVs) relying solely on lithium-ion (Li-ion) batteries face limitations related to range, mass, charging time, and battery downsizing. This study develops a dynamic system-level modeling framework for integrating an aluminum–air (Al–air) battery with a Li-ion traction battery within a MATLAB/Simulink electric vehicle platform. Two integration strategies were evaluated: (i) Al–air operation as a range extender activated through SOC-based control logic, and (ii) Al–air operation as an auxiliary power unit supplying non-traction loads. The Al–air subsystem was implemented using an experimentally informed polarization-based model coupled with aluminum consumption tracking and DC–DC converter integration. Vehicle performance was evaluated under UDDS, HWFET, WLTP, and FTP-75 drive cycles. Results show that coupling a 24.6 kWh Al–air pack with a downsized 20.3 kWh Li-ion pack enabled driving ranges of 379 km (UDDS), 523 km (HWFET), and 450 km (WLTP), exceeding the baseline full-capacity Li-ion configuration while reducing total battery-system mass by more than 50%. When operated as an auxiliary power unit under a constant 3 kW auxiliary load, the Al–air system increased the vehicle range by 44–96 km depending on the drive cycle. The results demonstrate the feasibility of Al–air-assisted dual-energy-storage architectures for extending the EV range while reducing dependence on large Li-ion battery packs. Full article

Understanding lithium distribution and transport within Li-ion battery components is critical in improving battery longevity, safety and performance. This study investigates lithium concentration profiles across the interface of an aluminum-doped Li₇La₃Zr₂O₁₂ (Al-LLZO) solid electrolyte and a lithium metal anode using Nuclear Reaction Analysis (NRA), a non-destructive depth-profiling technique. The Al-LLZO electrolyte was synthesized via electrospinning, producing nanofibers, which were subsequently sintered into pellets of average thickness 380 µm. These pellets were integrated into a Li|Al-LLZO|NMC-111 half-cell and cycled at 0.1 C for 1, 3, and 10 cycles, indicating pronounced lithium accumulation at the electrolyte–anode interface. Using NRA, this study provided a clear pathway for better understanding lithium transport and interfacial behavior, by quantitatively measuring the lithium distribution at the Al-LLZO electrolyte–electrode interface, and to look at the changes at this interface over the battery cycles. Full article

To address the critical industry challenges of insufficient thermal safety and reliability in the stacking design of lithium-ion battery (LIB) modules, as well as the lack of accurate traceability methods for LIB fire accidents, this study takes commercial 18650-type lithium, nickel cobalt aluminum (NCA) LIBs as the research object. First, we systematically investigated the thermal runaway (TR) behavior of single cells under thermal and electrical abuse conditions, identified the significant discrepancies in TR behavior between the two abuse scenarios, quantitatively revealed a positive correlation between TR risk and state of charge (SOC), and determined that the core feature is that the maximum heat release occurs in the negative electrode of the battery. Subsequently, we quantitatively analyzed the influences of the initial TR trigger position and module stacking structure on the TR propagation characteristics within the module, and obtained the key conclusions that center-triggered TR exhibits a faster propagation rate and that the vertical stacking structure significantly aggravates the TR chain reaction. Finally, based on the TR process, this paper summarizes the burn mark characteristics caused by different triggers of thermal runaway in LIBs. The results of this study provide critical fundamental data for optimizing the thermal safety design of LIB modules, and offer a scientific basis for the formulation of LIB fire rescue schemes and the implementation of fire investigation. Full article

The growing production of lithium-ion batteries is leading to an increase in waste, which contains elements considered critical in industry, like cobalt, manganese and nickel. Urban mining offers an opportunity to recover these elements and reintroduce them into the value chain. This study aimed to detect and recover metals of interest present in discarded lithium-ion batteries and determine the influence of flotation operating parameters on the recovery of the detected elements through an experimental design. The batteries subjected to the flotation experiments were obtained from various types of common disused mobile devices. They were dismantled by separating the copper sheets from the anode and the aluminum sheets from the cathode, to be subjected to a comminution process and elemental composition analysis using X-ray fluorescence. Only the cathode components were subjected to flotation. The flotation process was carried out by controlling the level of agitation and aeration and the flotation time using an automated flotation cell. The experiments were configured in a 2³ experimental design. Average recoveries of approximately 67% for cobalt, 64% for manganese, and 63% for nickel were achieved at a pH of 12.5 and a pulp density of 3.33 g/L using MIBC as the sole reagent. Statistical analysis at a 95% confidence level identified agitation, aeration, and flotation time both individually and in combination as significant factors. Linear models were developed to predict metal recovery, showing good agreement with experimental data (errors < 10%; standard deviation < 3%). Full article

The commercialization of lithium metal batteries is hindered by critical challenges such as uncontrollable lithium dendrite growth and interfacial instability. Constructing functional nanocoatings on separator surfaces represents an effective strategy to address these issues. In this study, a uniform aluminum-doped zinc oxide (AZO) modification layer was deposited on the separator via magnetron sputtering to enhance the electrochemical performance and safety of lithium metal batteries. The AZO layer combines the functions of a physical barrier and an interfacial regulator. On one hand, it effectively suppresses lithium dendrite penetration through the separator. On the other hand, its surface properties facilitate uniform lithium-ion transport and reduce the deposition overpotential. Experimental results demonstrate that the symmetric cells employing AZO-modified separators exhibit significantly reduced and stable lithium deposition overpotentials. In full cells assembled with a nickel cobalt aluminum (NCA) cathode, the system demonstrates higher specific capacity and notably extended cycle life compared to cells using unmodified polyethylene (PE) separators. This work proposes a practical strategy based on AZO-modified separators, offering a promising pathway toward the development of next-generation lithium metal batteries with high energy density and improved safety. Full article

This study systematically investigates the effects of the final annealing temperature on the microstructural evolution and mechanical properties of an Al-Fe-Si alloy aluminum foil. Scanning electron microscopy (SEM) characterization and tensile tests are employed for analysis. As the annealing temperature is elevated from 240 °C to 360 °C, the average grain size increases monotonically from 5.2 μm to 9.6 μm. Continuous recrystallization is identified as the predominant grain growth mechanism. Tensile deformation exhibits the homogeneous plastic behavior without localized necking. The tensile strength decreases significantly in the range of 240–300 °C and subsequently undergoes a recovery stage at 300–360 °C. Significant elongation anisotropy is observed. The maximum elongation reaches 30–34% in the 45° direction, relative to the rolling direction (RD), which is approximately 1.5 times that along the RD (0°). Comparative analysis of the anisotropy indices demonstrates that the aluminum foil annealed at 240 °C achieves the minimal tensile strength anisotropy (13.0 MPa) and elongation anisotropy (−4.2%). This indicates an optimal comprehensive mechanical performance. These findings provide a theoretical rationale for the industrial optimization of the annealing processes for Al-Fe-Si alloy foils. They are particularly valuable for balancing microstructural regulation and mechanical property enhancement in lithium-ion battery soft-packaging applications. Full article