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The fastest growth in electricity demand in the industrialized world will likely come from the broad adoption of artificial intelligence (AI)—accelerated by the rise of generative AI models such as OpenAI’s ChatGPT. The global “data center arms race” is driving up power demand and grid stress, which creates local and regional challenges because people in the area understand that the additional data center-related electricity demand is coming from faraway places, and they will have to support the additional infrastructure while not directly benefiting from it. So, there is an incentive for the data center operators to manage the fast and unpredictable power surges internally so that their loads appear like a constant baseload to the electricity grid. Such high-intensity and short-duration loads can be served by hybrid energy storage systems (HESSs) that combine multiple storage technologies operating across different timescales. This review presents an overview of energy storage technologies, their classifications, and recent performance data, with a focus on their applicability to AI-driven computing. Technical requirements of storage systems, such as fast response, long cycle life, low degradation under frequent micro-cycling, and high ramping capability—which are critical for sustainable and reliable data center operations—are discussed. Based on these requirements, this review identifies lithium titanate oxide (LTO) and lithium iron phosphate (LFP) batteries paired with supercapacitors, flywheels, or superconducting magnetic energy storage (SMES) as the most suitable HESS configurations for AI data centers. This review also proposes AI-specific evaluation criteria, defines key performance metrics, and provides semi-quantitative guidance on power–energy partitioning for HESSs in AI data centers. This review concludes by identifying key challenges, AI-specific research gaps, and future directions for integrating HESSs with on-site generation to optimally manage the high variability in the data center load and build sustainable, low-carbon, and intelligent AI data centers. Full article

In this work, a method for leaching black mass from spent Li batteries using oxalic acid was developed and experimentally verified with the objective of selectively separating lithium and cobalt. Oxalic acid proved to be an efficient and selective leaching agent. Under 1 M C₂H₂O₄, 120 min, L:S = 20, 80 °C and 300 rpm, a lithium yield of 90% was achieved, while cobalt dissolution remained low at 1.57%. Subsequently, cobalt spontaneously precipitated from the leachate within several hours, and the solid phase was fully separated after 24 h. The leachate contained minor amounts of accompanying metals, with dissolution yields of 0.5% Mn, 8% Fe and 1.4% Cu. These impurities were removed from the leachate by controlled pH adjustment using NaOH at ambient temperature and 450 rpm, with complete precipitation at pH 12. This procedure generated a purified lithium-rich leachate, which was converted into lithium oxalate by crystallisation at 105 °C. Subsequent calcination of the resulting solid at 450 °C for 30 min produced Li₂CO₃ with a purity of 91%. Based on the experimental findings, a conceptual technological process for selective lithium leaching using oxalic acid was proposed, demonstrating the potential of this method for sustainable lithium recovery. Full article

The rise in electric vehicles (EVs) with lithium-ion batteries supports net-zero goals, but the increasing demand will inevitably generate more battery waste. Current pack designs often rely on permanent joining techniques, which hinder disassembly and thereby limit serviceability, reuse and recycling. A critical challenge is the removal of the battery lid, typically bonded to the pack frame with sealant adhesives. In the absence of design for disassembly requirements for OEMs, this study investigates a novel debonding strategy focused on the lid-to-frame bonding. A silane-based adhesive commonly used in battery packs is first characterised under tensile, shear and mode I conditions to establish the baseline performance in the range of flexible adhesive properties. Herein, a heat-activated primer is introduced as a debondable interfacial layer between the adhesive and the substrate. Upon activation at 150 ${}^{\circ }$C, the primer significantly reduces adhesion, around 98% of the initial joint strength, enabling room temperature debonding. The primer demonstrates strong compatibility with epoxy and polyurethane adhesives, but its performance with silane-based systems still needs to be improved in terms of the primer’s compatibility with silane-based adhesives. Finally, a small-scale testing apparatus is developed to evaluate primer effectiveness in the disassembly of battery lids. This approach represents a promising step toward more serviceable, recyclable and sustainable battery systems. Full article

Accurate prediction of lithium battery remaining useful life (RUL) is crucial for battery management systems to monitor battery health status. However, RUL prediction remains challenging due to capacity non-stationarity caused by capacity regeneration phenomena. Therefore, this study proposes a novel RUL prediction framework that combines a two-stage decomposition strategy with a parallel Informer-LSTM architecture. First, STL decomposition is employed to decompose the capacity sequence into trend, seasonal, and residual components. The VMD method further refines the residual component from STL, extracting the underlying multiscale subsignals. Subsequently, a parallel dual-channel prediction network is constructed: the Informer branch captures global long-range dependencies to prevent trend drift, while the LSTM branch models local nonlinear dynamics to reconstruct fluctuations associated with capacity regeneration. Experiments on the NASA dataset demonstrate that this framework achieves an MAE below 0.0109, an RMSE below 0.0160, and an R² above 0.9950. Additional validation on the Oxford battery dataset confirms the model’s robust generalization capability under dynamic conditions, with an MAE of 0.0017. This further demonstrates that the proposed RUL prediction framework achieves significantly enhanced prediction accuracy and stability, offering a reliable solution for battery health status detection in battery management systems. Full article

In the context of small, battery-powered systems, a lightweight, reusable architecture is needed for integrated measurement, visualization, and cloud telemetry that minimizes hardware complexity and energy footprint. Existing solutions require high resources. This limits their applicability in Internet of Things (IoT) devices with low power consumption. The present work demonstrates the process of design, implementation and experimental evaluation of a single-cell lithium-ion battery monitoring prototype, intended for standalone operation or integration into other systems. The architecture is compact and energy efficient, with a reduction in complexity and memory usage: modular architecture with clearly distinguished responsibilities, avoidance of unnecessary dynamic memory allocations, centralized error handling, and a low-power policy through the usage of deep sleep mode. The data is stored in a cloud platform, while minimal storage is used locally. The developed system combines the functional requirements for an embedded external battery monitoring system: local voltage and current measurement, approximate estimation of the State of Charge (SoC) using a look-up table (LUT) based on the discharge characteristic, and visualization on a monochrome OLED display. The conducted experiments demonstrate the typical U(t) curve and the triggering of the indicator at low charge levels (LOW − SoC ≤ 20% and CRITICAL − SoC ≤ 5%) in real-world conditions and the absence of unwanted switching of the state near the voltage thresholds. Full article

In recent years, the energy revolution has driven the rapid development of lithium-ion batteries (LIBs). A fire suppression system capable of rapidly and effectively extinguishing LIB fires constitutes the last line of defense for ensuring the safe operation of the LIB industry. In this study, an experimental platform simulating the storage environment of LIBs in energy-storage stations was constructed, and liquid nitrogen (LN) was employed to conduct fire suppression tests on LIBs. The effective utilization of 17.4 kg of LN during the suppression process inside the battery module was quantified. In addition, fire compartments were established within the battery module, and a strategy for enhancing the LN suppression effectiveness was proposed. The results indicate that, without intervention, the thermal runaway propagation (TRP) rate within the LIB module gradually accelerates. After LN injection, the effective utilization of LN for extinguishing individual LIBs decreases progressively along the sequence of TRP. Creating fire compartments inside the PACK using 6 mm aerogel blankets effectively reduces the transfer of energy from the region undergoing thermal runaway (TR) to other regions, while simultaneously enhancing the extinguishing performance of LN. Under the same LN dosage, the introduction of fire compartments increases the effective utilization from 0.037 to 0.051. However, as the compartment volume decreases, the degree of improvement in LN utilization is reduced. This work is expected to provide guidance for the engineering application of LN-based fire suppression systems to inhibit LIB TR and its propagation. Full article

The widespread adoption of lithium-ion battery-powered electric vehicles has raised increasing concerns regarding battery safety under mechanical abuse conditions. However, mechanical abuse scenarios, such as battery extrusion, are highly diverse, making it impractical to conduct extensive destructive experiments and independent modeling for each specific scenario. In this work, a cross-scenario mechanical safety modeling framework for lithium-ion batteries is proposed based on transfer learning. Three quasi-static mechanical abuse tests, including flat-plate, rigid-rod, and hemispherical compression, are conducted on 18650 lithium-ion batteries. An equivalent mechanical model with a spring–damper parallel structure is employed to characterize the mechanical response and generate simulation data. Based on data from a single mechanical abuse scenario, a backpropagation neural network (BPNN)-based safety model is established to predict the maximum stress in the battery. The learned knowledge is then transferred to other mechanical abuse scenarios using a transfer learning strategy. The results demonstrate that, under limited target-domain data, the transferred models achieve stable prediction performance, with the average relative error controlled within 3.6%, outperforming models trained from scratch under the same conditions. Compared with existing studies that focus on single-scenario modeling, this work explicitly investigates cross-scenario transferability and demonstrates the effectiveness of transfer learning in reducing experimental and modeling effort for battery mechanical safety analysis. Full article

This work provides an overview of the mechanics of lithium-ion batteries, both from the aging and diagnostics perspective. Battery diagnostics based on mechanical measurements exploit the strong correlation between electrode lithiation and its deformation, resulting in macroscopic cell deformation. Macroscopic deformation is then a proxy for lithium concentration, enabling estimation of state of charge (SOC) and degradation indicators such as loss of active material and lithium inventory. The results demonstrate that SOC estimation algorithms based on deformation measurements are more robust than voltage-based methods, which are sensitive to temperature and aging, requiring constant updates of the algorithm parameters. Moreover, the health of the battery can be assessed through the differential expansion method even under high-current operation, providing results consistent with the traditional differential voltage method but applicable to real-world industrial applications. Mechanics plays a crucial role also in battery degradation. This work presents the application of POLIDEMO, an advanced battery aging model that explicitly accounts for mechanical degradation phenomena, providing a physics-based framework describing the coupled electrochemical–mechanical aging processes in lithium-ion batteries. It enables the prediction of key degradation indicators, including capacity fade—capturing the characteristic knee-point behavior—and the irreversible battery thickness increase associated with long-term aging. The model is validated with multiple aging datasets, demonstrating that parameters calibrated under a single operating condition can accurately predict degradation across diverse aging scenarios. Full article

Battery management systems (BMSs) are integral components of electric vehicles (EVs), as they ensure the safe and efficient operation of lithium-ion batteries. State of health (SoH) estimation is one of the core functions of BMSs, providing an assessment of the current condition of a battery, while prognostics aim to predict remaining useful life (RUL) as a function of the battery’s condition. An accurate SoH estimation allows proactive maintenance to prolong battery lifespan. Traditional SoH estimation methods can be broadly divided into experiment-based and model-based approaches. Experiment-based approaches rely on direct physical measurements, while model-driven approaches use physics-based or data-driven models. Although experiment-based methods can offer high accuracy, they are often impractical and costly for real-time applications. With recent advances in artificial intelligence (AI), deep learning models have emerged as powerful alternatives for SoH prediction. This paper offers an in-depth examination of AI-driven SoH prediction technologies, including their historical development, recent advancements, and practical applications, with particular emphasis on the implementation of widely used AI algorithms for SoH prediction. Key technical challenges associated with SoH prediction, such as computational complexity, data availability constraints, interpretability issues, and real-world deployment constraints, are discussed, along with possible solution strategies. Full article

Waterborne polyurethane (WPU) and waterborne poly(urethane-urea) (WPUU) dispersions allow safer and more sustainable manufacturing of rechargeable batteries via water-based processing, while offering tunable adhesion and segmented-domain mechanics. Beyond conventional roles as binders and coatings, WPU/WPUU chemistries also support separator/interlayer and polymer-electrolyte designs for lithium-ion and lithium metal systems, where interfacial integrity, stress accommodation, and ion transport must be balanced. Here, we review WPU/WPUU fundamentals (building blocks, dispersion stabilization, morphology, and film formation) and review prior studies through a battery-centric structure–processing–property lens. We point out key performance-limiting trade-offs—adhesion versus electrolyte uptake and ionic conductivity versus storage modulus—and relate them to practical formulation variables, including soft-/hard-segment selection, ionic center/counterion design, molecular weight/topology control, and crosslinking strategies. Applications are reviewed for (i) electrode binders (graphite/Si; cathodes such as LFP and NMC), (ii) separator coatings and functional interlayers, and (iii) gel/solid polymer electrolytes and hybrid composites, with a focus on practical design guidelines for navigating these trade-offs. Future advancements in WPU/WPUU chemistries will depend on developing stable, low-impedance interlayers, enhancing electrochemical behavior, and establishing application-specific design guidelines to optimize performance in lithium metal batteries (LMB). Full article

The increasing application of lithium-ion batteries in manufacturing and energy storage systems necessitates high-precision screening of abnormal cells during manufacturing, so as to ensure safety and performance. Existing methods struggle to break down the barrier between prior knowledge and data, suffering from limitations such as insufficient detection accuracy and poor interpretability. This becomes even more prominent when facing distributional shifts in data. In this study, we propose a knowledge-enhanced anomaly detection framework for cell screening. This framework integrates domain knowledge, such as electrochemical principles, expert heuristic rules, and manufacturing constraints, into data-driven models. By combining features extracted from charging/discharging curves with rule-based prior knowledge, the proposed framework not only improves detection accuracy but also enables a traceable reasoning process behind anomaly identification. Experiments based on real-world battery production data demonstrate that the proposed framework outperforms baseline models in both precision and recall, making it a promising preferred solution for quality control in intelligent battery manufacturing. Full article

The global shipping industry is surging ahead, and with it, a quiet revolution is taking place on the water: marine lithium-ion batteries have emerged as a crucial clean energy carrier, powering everything from ferries to container ships. When these vessels dock, they increasingly rely on shore power charging systems to refuel—essentially, plugging in instead of idling on diesel. But predicting how much power they will need is not straightforward. Think about it: different ships, varying battery sizes, mixed charging technologies, and unpredictable port stays all come into play, creating a load profile that is random, uneven, and often concentrated—a real headache for grid planners. So how do you forecast something so inherently variable? This study turned to the Monte Carlo method, a probabilistic technique that thrives on uncertainty. Instead of seeking a single fixed answer, the model embraces randomness, feeding in real-world data on supply modes, vessel types, battery capacity, and operational hours. Through repeated random sampling and load simulation, it builds up a realistic picture of potential charging demand. We ran the numbers for a simulated fleet of 400 vessels, and the results speak for themselves: load factors landed at 0.35 for conventional AC shore power, 0.39 for high-voltage DC, 0.33 for renewable-based systems, 0.64 for smart microgrids, and 0.76 when energy storage joined the mix. Notice how storage and microgrids really smooth things out? What does this mean in practice? Well, it turns out that Monte Carlo is not just academically elegant, it is practically useful. By quantifying uncertainty and delivering load factors within confidence intervals, the method offers port operators something precious: a data-backed foundation for decision-making. Whether it is sizing infrastructure, designing tariff incentives, or weighing the grid impact of different shore power setups, this approach adds clarity. In the bigger picture, that kind of insight matters. As ports worldwide strive to support cleaner shipping and align with climate goals—China’s “dual carbon” ambition being a case in point—achieving a reliable handle on charging demand is not just technical; it is strategic. Here, probabilistic modeling shifts from a simulation exercise to a tangible tool for greener, more resilient port energy management. Full article

Lithium-ion batteries (LIBs) face the safety hazard of thermal runaway (TR). Gas-sensing-based monitoring is one of the viable warning approaches for batteries during operation, and TR warning using semiconductor gas sensors has garnered widespread attention. This review presents a comprehensive analysis of the latest advances in this field. It details the gas release characteristics during the TR failure process and identifies H₂, electrolyte vapor, CO, CO₂, and CH₄ as effective TR warning markers. The core of this review lies in an in-depth critical analysis of gas-sensing materials designed for these target gases, systematically summarizing the design, performance, and application research of semiconductor gas-sensing materials for each aforementioned gas in battery monitoring. We further summarize the current challenges of this technology and provide an outlook on future development directions of gas-sensing materials, including improved selectivity, integration, and intelligent advancement. This review aims to provide a roadmap that directs the rational design of next-generation sensing materials and fast-tracks the implementation of gas-sensing technology for enhanced battery safety. Full article

To address the limitations of traditional lithium battery defect detection—low efficiency, high missed detection rates for minute/composite defects, and inadequate multimodal fusion—this study develops an improved YOLOv8 model based on multimodal fusion and attention enhancement for unified full-lifecycle multi-type defect detection. Integrating visible-light and X-ray modalities, the model incorporates a Squeeze-and-Excitation (SE) module to dynamically weight channel features, suppressing redundancy and highlighting cross-modal complementarity. A Multi-Scale Fusion Module (MFM) is constructed to amplify subtle defect expression by fusing multi-scale features, building on established feature fusion principles. Experimental results show that the model achieves an mAP@0.5 of 87.5%, a minute defect recall rate (MRR) of 84.1%, and overall industrial recognition accuracy of 97.49%. It operates at 35.9 FPS (server) and 25.7 FPS (edge) with end-to-end latency of 30.9–38.9 ms, meeting high-speed production line requirements. Exhibiting strong robustness, the lightweight model outperforms YOLOv5/7/8/9-S in core metrics. Large-scale verification confirms stable performance across the battery lifecycle, providing a reliable solution for industrial defect detection and reducing production costs. Full article

An accurate assessment of the state of health (SOH) of lithium-ion batteries (LIBs) is crucial for ensuring the safety and reliability of energy storage systems and electric vehicles. However, existing methods face challenges: physics-based models are computationally complex, traditional data-driven methods rely heavily on manual feature engineering, and single models lack the ability to capture both local and global degradation patterns. To address these issues, this paper proposes a novel hybrid LSTM–Transformer model for LIB SOH estimation using actual measurement data. The model integrates Long Short-Term Memory (LSTM) networks to capture local temporal dependencies with the Trans-former architecture to model global degradation trends through self-attention mechanisms. Experimental validation was conducted using eight 18650 Nickel Cobalt Manganese (NCM) LIBs subjected to 750 charge–discharge cycles under room temperature conditions. Sixteen statistical features were extracted from voltage and current data during constant current–constant voltage (CC-CV) phases, with feature selection based on the Pearson correlation coefficient and maximum information coefficient analysis. The proposed LSTM–Transformer model demonstrated superior performance compared to the standalone LSTM and Transformer models, achieving a mean absolute error (MAE) as low as 0.001775, root mean square error (RMSE) of 0.002147, and mean absolute percentage error (MAPE) of 0.196% for individual batteries. Core features including cumulative charge (CC Q), charging time, and voltage slope during the constant current phase showed a strong correlation with the SOH (absolute PCC > 0.8). The hybrid model exhibited excellent generalization across different battery cells with consistent error distributions and nearly overlapping prediction curves with actual SOH trajectories. The symmetrical LSTM–Transformer hybrid architecture provides an accurate, robust, and generalizable solution for LIB SOH assessment, effectively overcoming the limitations of traditional methods while offering potential for real-time battery management system applications. This approach enables health feature learning without manual feature engineering, representing an advancement in data-driven battery health monitoring. Full article