Search Results (1,682)

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

Thermal regulation of lithium-ion (Li-ion) battery modules is a critical constraint for electric vehicle (EV) safety and durability, particularly during high-C-rate operation. Phase change materials (PCMs) have emerged as promising passive solutions due to their latent heat storage capability; however, current literature is heavily biased toward organic paraffin-based systems and lacks structured benchmarking across PCM categories and integration architectures. This review provides a systematic comparative assessment of PCM-based battery thermal management systems (BTMSs) comprising organic, inorganic, and eutectic materials under EV-relevant discharge conditions. The review is structured according to the conventional classification of PCMs; however, the available literature is predominantly focused on organic materials, particularly paraffin-based PCMs, leading to greater depth of analysis for this category. Thermophysical properties are analyzed in conjunction with discharge rate, module configuration, and hybrid cooling strategies. The results indicate that peak temperature mitigation is weakly correlated with latent heat magnitude when thermal conductivity remains below critical values. Conductivity-enhanced composites incorporating expanded graphite or metal foams significantly improve heat diffusion, reducing hotspot intensity and inter-cell temperature gradients under medium-to-high C-rates. Pure passive PCM systems exhibit thermodynamic limitations during sustained high-power operation due to saturation effects, underscoring the need for hybrid architectures for continuous heat rejection. This work establishes a structured benchmarking framework and demonstrates that effective thermal conductivity, integration strategy, and discharge-dependent design dominate BTMS performance over latent heat alone. The findings also reveal that inorganic and eutectic PCM-based BTMSs remain comparatively less explored in the literature, particularly at the battery module level and under realistic electric vehicle operating conditions, highlighting opportunities for future research. Full article

Ionic liquid-based localized high-concentration electrolytes, leveraging their intrinsically nonflammable safety characteristics and wide electrochemical windows, have emerged as strong contenders for next-generation lithium metal battery electrolytes. However, because such systems are anion-rich, the electrolyte bulk phase tends to form solvation structures dominated by bulky anionic clusters along with an excess of free anions, which triggers persistent and uncontrollable anion decomposition at the interphase. To address this issue, we adopt a strategy of constructing a compressed solvation structure by introducing a weakly interacting chlorinated diluent (TeCA), which helps form a compact solvation environment and alleviates excessive anion decomposition at electrode interphases. In this work, 1,1,2,2-tetrachloroethyl acetate (TeCA) was introduced as a weakly coordinating chlorinated diluent into an ionic-liquid localized high-concentration electrolyte (LHCE) to regulate the Li⁺-FSI⁻ solvation environment. By combining Raman spectroscopy, molecular dynamics simulations, and electrochemical characterization, the TeCA-LHCE system was found to exhibit altered ion-cluster configurations, improved oxidation tolerance, and enhanced interfacial stability under high-voltage conditions. The as-prepared TeCA-LHCE electrolyte presents improved electrochemical performance in comparison with TTE-LHCE and the baseline electrolyte (BE). The Li||Cu half-cell employing TeCA-LHCE achieved a high Coulombic efficiency above 99% over 500 cycles and formed a uniform and dense lithium deposition layer without obvious dendritic growth. When paired with a high-loading NCM811 cathode (10 mg cm⁻²), the TeCA-LHCE-based Li||NCM811 full cell delivered significantly improved cycling stability and rate capability under a high cutoff voltage of 4.3 V. Full article

The poor thermal stability and inferior ion transport performance of polyolefin separators have been the bottlenecks restricting the development of lithium ion battery (LIB)-based high-power energy storage systems. Thus, the preparation of advanced separators is essential as the alternative of traditional polyolefin for reliable LIB-based large-scale grid energy storage. In this study, a composite polyimide-based separator doped with a lithium-conducting inorganic was prepared by electrospinning combined with in situ thermal imidization as the matrix. The effects of the inorganic and thermal treatment conditions on the structure and performance of the separator were systematically investigated. The results show that the optimized composite separator exhibits excellent comprehensive performance: (1) its thermal stability is significantly better than that of commercial polyolefin separators, with no obvious size shrinkage at high temperatures; (2) the porosity and electrolyte wettability are greatly improved, effectively promoting the uniform transport and desolvation process of lithium ions, and the ion transport performance is significantly enhanced; and (3) the mechanical properties meet the requirements for commercial batteries. In half-cell tests, the composite separator achieved excellent rate performance and cycling stability. Particularly, overcharge tests for the assembled pouch cells with Ah-level were performed, where the low overcharge temperature verified the better thermal stability of the composite separator than that of batteries assembled with traditional commercial separators. This study provides new ideas and technical support for the design and industrial application of high-safety and long-life energy storage battery separators. Full article

To date, lithium–ion batteries (LIBs) are considered one of the most promising and market-leading energy storage systems due to their high theoretical capacity and energy density. However, poor thermal and cyclic stability, low electrolyte uptake, and the possibility for frequent short circuits of typical separators and evolution of several gases during long cycle operation pose several problems for LIBs. Metal-organic frameworks (MOFs) have attracted widespread interest as a promising material for improving the cycle stability and safety of rechargeable batteries due to their inherent surface and structural properties such as high specific surface area, high porosity, and ionic conductivity. In this work, the aim is to provide detailed descriptions of the synthesis routes and parameters for obtaining various MOFs such as Zr-MOF-808 and Ni-MOF-74 nanoparticles and the fabrication of those MOF-integrated separators. To optimize the crystallinity, morphological and compositional characteristics, and several material characterizations such as XRD, SEM, and EDX have been applied. Afterwards, the synthesized MOF-integrated glass fiber (GF) separators have been developed for lithium–ion battery (LIB) applications. To investigate the electrochemical performance and the effect of MOF integration into the separators, electrochemical studies in the form of galvanostatic charge–discharge (GCD), electrochemical impedance spectroscopy (EIS) have been evaluated by preparing CR2032-type half-coin cells. This MOFs-integrated GF-separators and synthesized LiNi_0.6Mn_0.2Co_0.2O₂ (NMC622) cathode materials-based coin cell LIB exhibited higher cycle stability than bare GF-separator based LIB. This novel approach and extensive research suggest that development of MOF-integrated separators could significantly improve cycle stability by reducing the internal cell degradation for next generation energy storage devices. Full article

Temperature monitoring is critical for lithium-ion battery (LIB) safety and performance, yet instrumenting every cell in a commercial pack remains impractical due to cost and wiring constraints. Existing sensorless methods rely on either physics-based thermal models requiring extensive parameterization or nonlinear recurrent estimators that cannot integrate sensor feedback when measurements become available. Motivated by these limitations, this paper proposes a Deep Koopman observer that enforces linear latent dynamics, enabling direct compatibility with Kalman filtering. The observer estimates surface temperature from four standard BMS signals and two exponential moving averages of squared current that capture thermal memory at distinct time scales, operating in two modes: fully sensorless for uninstrumented cells, or sensor-fused via a one-state EKF when a thermistor is available. Evaluated under strict cell-to-cell split across twelve drive cycles and five ambient temperatures, the open-loop observer achieves 17% lower error than the strongest reproduced CNN-LSTM baseline without online resistance identification or thermal-model simulation, and the EKF path delivers a further 35% reduction over the open-loop estimate. The evaluation is limited to a single cell chemistry and manufacturing batch; cross-chemistry and aging validation remain for future work. Full article

Lithium-ion batteries with high energy density and long cycle life have been widely used as secondary batteries in electric vehicles and energy storage systems. With the growing demand for high energy density in lithium-ion batteries, silicon-based materials, which possess a high theoretical specific capacity (4200 mAh g⁻¹), are regarded as core candidates for anode materials. However, Si-based materials undergo severe volume expansion (up to 300%), which leads to the collapse of the electrode structure, inducing pulverization of the active material and capacity loss, thereby hindering the commercial application of silicon-based materials. To address these issues, scholars from various countries have developed many silicon-based materials with different compositions and three-dimensional structures, and have made some research progress. This review first elaborates on the lithium storage mechanisms and advantages of diverse silicon-based anode materials by taking Si, SiO_x, SiN_x, and SiP_x as representative examples with distinct characteristics. Subsequently, from the two aspects of dimensional design (0D, 1D, 2D and 3D) and architecture design (core–shell, sandwich-like and network structure), the design strategies for various silicon-based anode structures and their enhancement on electrochemical performance are analyzed. Finally, this review elucidated the challenges faced by silicon-based anodes from the perspectives of mechanism elucidation, structural customization, industrialization, and full-cell applications. It also proposed future development directions for silicon anodes by combining actual challenges and focusing on aspects such as structure optimization, machine learning, advanced characterization techniques, and mechanistic analysis. Full article

Lithium-ion batteries (LIBs) are subject to mechanical abuse both in electric vehicles and consumer electronic applications when dropped, which can lead to capacity degradation even if the cells survive the impact. This study investigates the impact of mechanical damage on the electrochemical performance of LIBs, focusing on capacity retention and internal resistance changes. The batteries were subjected to dynamic mechanical impact using varying impact energies (3J, 5J, and 7J) while measuring internal resistance and capacity before and after the impact. Hybrid Pulse Power Characterization (HPPC) was employed to assess internal resistance and capacity degradation across multiple cycles. Our results demonstrate that even minor mechanical damage can cause significant performance decay, especially after several cycles. The study also reveals that the state of charge (SOC) prior to impact has a minimal effect on the survival rate of the cells but influences the extent of damage observed. Post-impact analysis using optical microscopy indicates structural damage, including separator tears and delamination, contributing to capacity fade. This work highlights the importance of considering intermediate mechanical damage in LIB safety and performance assessments. 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

Short circuits and subsequent fires resulting from objects impacting the bottom of vehicle power battery packs considerably jeopardize electric vehicle (EV) operations. This study investigated underbody impacts in EVs and the overall mechanical properties of battery cells. Key features of road debris were extracted and simplified to establish a geometric parameter structure model and determine realistic battery pack responses to debris impact. Quasi-static compression and dynamic impact tests on a prismatic lithium-ion battery (LIB) and power battery pack followed. Macroscopic mechanical responses, deformation failure modes, and internal jellyroll damage of cells and packs were evaluated, and constitutive equations and failure parameters were derived to develop a finite element model, whose effectiveness and reliability were verified by comparing simulation results with experimental data. Finally, a homogenized model of the prismatic LIB and power battery pack was constructed, which effectively predicted the macroscopic mechanical response and internal short-circuit failure under mechanical loading. However, simulation and test results revealed certain deviations in cell indentations under battery pack bottom impacts, presumably because the FEMs neglect the dynamic strain rate effects of electrolyte and cooling liquid. Overall, this study elucidates safety risks to cells and their key components under power battery pack bottom impacts. Full article

The adoption of lithium-ion batteries (LIBs) as secondary rechargeable batteries across many industries, including consumer electronics, electromobility, industrial tools, and electrical energy storage, is on the rise. As lithium-ion batteries approach the end of their life, there is a need to assess them for the possibility of a secondary application or reuse for a less demanding application. The extra connections of individual cells, BMS, temperature sensors, and other components to form a compact battery pack pose a challenge for second-life assessment, which usually prefers to separate individual cells for testing before discarding very bad cells for recycling and grading cells with substantive capacity based on their remaining capacity. This is a high cost for the second-life assessment. This work seeks to investigate an approach that avoids dismantling the battery pack into individual modules, cells, and BMS by including a BMS feature that allows the capacity and power ratings to be rescaled onboard after its first use. A set of cells with different chemistries was used in this work: a nickel–cobalt–aluminium oxide cathode with a silicon-doped graphite anode (NCA-GS), a nickel–cobalt–aluminium oxide cathode and graphite, and a lithium–nickel–manganese–cobalt oxide (NMC) cathode with a graphite anode (NMC-G) with various ageing states and behaviours. Their internal resistance and capacity at the beginning and end of life were compared. The scaling factor was obtained by finding the square root of the ratio of the internal resistance at EOL to that at BOL. With the current obtained by multiplying the cycling current rate by the rescaling factor, the surface temperature profile of the aged cells during cycling became the same as the temperature at the beginning of life. The relaxation voltage after discharge to 0% SOC and charge to 100% SOC was used to set the low and high cut-off voltages, respectively. This contributed significantly to reduced ageing and to a lower temperature rise in the spent cells. This set the stage for rescaling or derating battery systems without separating the individual cells, which is a huge cost for second-life use of lithium-ion batteries. BMS can be designed with configurable voltage and current limits, so that when repurposed for a second life, only a simple configuration or firmware update may be necessary. Full article

Graphite is widely used as an anode in lithium-ion batteries (LIBs); however, its limited capacity restricts the energy density enhancement. Si-based anodes offer much higher capacity, but their significant volume changes during repeated lithiation and delithiation generate mechanical stress and can damage the electrode/current-collector interface. Herein, high-strength nanotwinned Cu (NT-Cu) was fabricated and employed as current collectors for carbon-coated Si/β-Si₃N₄-based anodes. The electroplated 5 μm-thick NT-Cu foils exhibited tensile strength exceeding 760 MPa. The role of the Cu current collector was investigated by comparing NT-Cu foils with different mechanical properties and commercial Cu foils. The results show that electrochemical performance was not governed by UTS alone; instead, a balanced combination of tensile strength, ductility, and surface morphology was important for improving cycling stability and rate capability. To further improve cycling retention, artificial graphite was incorporated into the Si/β-Si₃N₄ composite. Using a 5 μm electroplated NT-Cu foil and a Si/β-Si₃N₄/artificial graphite composite anode, the pouch cell retained 81.51% of its capacity and delivered 267.3 mAh g⁻¹ after 206 cycles. These results demonstrate the potential of NT-Cu for improving the stability of Si-containing LIB anodes. Full article

This two-year study proposes the application of industrial computed tomography (CT) as a complementary technique to conventional capacity and internal resistance measurements for evaluating not only the state of health (SOH) of different lithium-ion battery types used in electric vehicles, but also to predict its past. While commonly used assessment methods primarily focus on electrical properties of batteries, industrial CT allows non-destructive, three-dimensional visualization and systematic evaluation of internal structural changes within individual battery cells and allows to compare different lithium battery type internal structure changes. The study investigates two lithium-ion battery chemistries: lithium iron phosphate (LFP) and nickel manganese cobalt oxide (NMC). The effects of different discharge rates (1C, 2C, and 3C) on battery degradation were analyzed by comparing CT scan data obtained for the cells in their initial (new) condition and after reaching 60% SOH following cycling-induced aging. The findings provide improved understanding of the physical processes associated with battery aging under varying discharge conditions, enabling a more complete evaluation of battery health. Full article

High-nickel NCA/Si–C 21700 cells exhibit strongly condition-dependent degradation, but the coupled influence of temperature and rate on electrochemical, thermal, and structural evolution remains insufficiently resolved. Here, Samsung INR21700-50E cells were aged under a 3 × 3 matrix of ambient temperatures (0, 23, and 40 °C) and C-rates (0.5C, 1C, and 2C). Periodic reference performance tests were used to track capacity, 10 s direct-current internal resistance, electrochemical impedance, pseudo-open-circuit voltage, differential voltage/incremental capacity behavior, heat generation, and post-mortem morphology. Guided by the hypothesis that temperature and rate history change not only the speed but also the dominant pathway of aging, the results show that both ambient temperature and the charge/discharge rate program govern the aging trajectory. Low-temperature cycling accelerates capacity loss and resistance growth through severe polarization and lithium plating, indicating dominant loss of lithium inventory. High-temperature operation promotes interfacial side reactions, impedance rise, and cathode structural degradation, leading to stronger loss of active material at later stages. An increasing C-rate amplifies these effects by raising overpotential and thermal load. Heat generation power increases markedly with aging and depends strongly on temperature–rate history. Scanning electron microscopy confirms cathode cracking, anode surface film thickening, and separator degradation under severe conditions. These experimental indicators are integrated into a mechanism-aware diagnostic framework that maps capacity retention, DCIR/EIS parameters, ICA/DVA indices, and heat generation metrics to dominant aging modes, supporting BMS state-of-health estimation, lifetime prediction, thermal management, and second-life screening of high-nickel NCA cells. The condition-averaged trajectories are further converted into a semi-empirical aging law that links capacity loss, resistance growth, and heat generation increase for BMS-oriented lifetime prediction. Full article

Real-time monitoring of lithium-ion capacitors (LICs) is crucial for ensuring reliability and predictive maintenance in dynamic applications such as electric transportation. However, traditional electrochemical impedance spectroscopy (EIS) techniques are complex and costly for onboard diagnostics due to their reliance on external excitation signals and dedicated hardware. Therefore, this paper presents an innovative framework for online state of health (SOH) estimation that bypasses these limitations by utilizing fast Fourier transform (FFT)-based passive impedance extraction directly from operational current and voltage signals. From experimental data, the equivalent circuit model (ECM) is developed, as well as its parameters, such as ohmic resistance, charge-transfer resistance, and Warburg diffusion. These parameters are identified through the extraction of impedance points in the low frequency region through FFT and the series resistance point using ohmic measurement, then performing a periodic curve fitting to these points. These curve fittings provide extracted ECM parameters. These parameters are used with a trained model to estimate the SOH of the monitored cell and are updated online. The proposed method was experimentally validated on five LIC cells aged under various C-rates (1C, 4C, 7C) and temperatures (35 °C, 40 °C, 50 °C), showing consistent impedance evolution with capacity fade. Validation of the utilized machine learning models, such as Polynomial Regression (PR), principal components analysis (PCA), and random forest (RF) regression, achieved SOH prediction errors as low as 2.23% compared to experimental results. The developed framework is particularly suitable for applications such as flash-charged electric buses but is broadly applicable across other energy storage systems as well. This advanced method enables real-time diagnostics without hardware modification, offering significant potential for integration into existing battery management systems (BMSs). Full article