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Batteries
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Recent Progress of Battery Design, Modeling and Testing in Electric...
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Recent Progress of Battery Design, Modeling and Testing in Electric Vehicles

A special issue of Batteries (ISSN 2313-0105). This special issue belongs to the section "Battery Modelling, Simulation, Management and Application".

Deadline for manuscript submissions: 15 June 2025 | Viewed by 19281

Special Issue Editors

Dr. Jie Deng

E-Mail Website
Guest Editor
Energy Systems and Applied Sciences, Ford Motor Company, Dearborn, MI 48121, USA
Interests: lithium-ion batteries; battery system development; battery safety; battery thermal management; thermal runaway mitigation; multi-physics modeling and testing
Dr. Chulheung Bae

E-Mail Website
Guest Editor
Energy Systems and Applied Sciences, Ford Motor Company, Dearborn, MI 48121, USA
Interests: energy storage systems; lithium-Ion battery cell; module, and system design and validation; electroanalytical techniques; solid state battery; battery manufacturing

Special Issue Information

Dear Colleagues,

As electric vehicles (EVs) help reduce both petroleum dependence and greenhouse gas emissions, many automotive companies are currently adapting their global automotive businesses to accelerate the development and delivery of EVs. In current EVs, lithium-ion batteries are the most common energy sources. As a result of their commercialization, tremendous progress has been made to improve their capacity, cycle life and charging rate. Advances in battery technology drive the development of EVs, and their global volume has grown significantly in recent years. Nevertheless, to compete with internal combustion engine vehicles and further increase the EV market share, EV battery technology still faces numerous challenges (such as energy density, fast charging capacity, safety, etc.) that must be overcome.

For this Special Issue, we are seeking contributions in EV battery design, modeling and testing that can help to improve one or more attributes (such as energy density, power, fast charging capability, safety, or life) of EV batteries.

Topics of interest include (but are not limited to):

  • Battery cell and pack design that helps to improve the energy density, power, fast charging capability, safety, or life of the battery system in electric vehicles.
  • Battery thermal management that helps to keep battery temperature within limits under different scenarios.
  • Battery safety modeling and testing that help to understand battery behaviors in abuse conditions.
  • Battery failure (e.g., short-circuit) detection and prevention.
  • Battery thermal runaway behaviors and mitigation strategies.
  • Battery fast charging modeling, testing and protocols.
  • Battery materials that deliver high energy density and/or high-power, better safety, longer life of the cells.
  • Battery aging and life modeling and measurement.
  • Battery control, fault diagnose, and estimation of battery states.
  • Battery recycling.

Dr. Jie Deng
Dr. Chulheung Bae
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Batteries is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2700 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • battery cell design
  • battery pack design
  • battery thermal management
  • battery safety
  • battery failure detection
  • thermal runaway
  • fast charging
  • battery materials
  • battery aging
  • battery life
  • battery control
  • battery states estimation
  • battery recycling
  • battery life cycle assessment (LCA)

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  • Greater discoverability: Special Issues support the reach and impact of scientific research. Articles in Special Issues are more discoverable and cited more frequently.
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Further information on MDPI's Special Issue polices can be found here.

Published Papers (7 papers)

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Research

50 pages, 104911 KiB  
Article
Influence of the Arrangement of the Cells/Modules of a Traction Battery on the Spread of Fire in Case of Thermal Runaway
by Ana Olona and Luis Castejón
Batteries 2024, 10(2), 55; https://doi.org/10.3390/batteries10020055 - 3 Feb 2024
Cited by 2 | Viewed by 3088
Abstract
When designing the battery of an electric vehicle, different parameters must be considered to obtain the safest arrangement of the battery/modules/cells from the mechanical and thermal points of view. In this study, the thermal runaway propagation mechanism of lithium-ion cells is analyzed as [...] Read more.
When designing the battery of an electric vehicle, different parameters must be considered to obtain the safest arrangement of the battery/modules/cells from the mechanical and thermal points of view. In this study, the thermal runaway propagation mechanism of lithium-ion cells is analyzed as a function of their arrangement within a battery pack in case of a fire propagation of a battery pack in which a thermal runaway has occurred. The objective is to identify which cell/module arrangement is most critical within the battery pack, using microscopic analysis of the structure and chemical composition of the most damaged cells, both horizontally and vertically, of a battery belonging to a burnt vehicle. And their final condition was compared with the condition of new cells of the same type. In this way, the structure and chemical composition of the cathode, anode, and separator after thermal runaway were compared. This research was carried out to obtain information to understand the mechanical properties of lithium-ion cells and their behavior after thermal runaway heating leading to the propagation of a fire. Through the analysis carried out, it is concluded that cells placed in a vertical arrangement have worse behavior than cells in a horizontal arrangement. Regarding the safety of the battery, the results of this study will allow us to determine which arrangement and structure of the cells in the battery pack is safer against thermal runaway due to thermal failure. Full article
(This article belongs to the Special Issue Recent Progress of Battery Design, Modeling and Testing in Electric Vehicles)
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24 pages, 6306 KiB  
Article
Stress Distribution Inside a Lithium-Ion Battery Cell during Fast Charging and Its Effect on Degradation of Separator
by Mustapha Makki, Cheol W. Lee and Georges Ayoub
Batteries 2023, 9(10), 502; https://doi.org/10.3390/batteries9100502 - 2 Oct 2023
Cited by 3 | Viewed by 3375
Abstract
The automotive industry is rapidly transitioning to electric vehicles (EVs) in response to the global efforts to reduce greenhouse gas emissions. Lithium-ion battery (LIB) has emerged as the main tool for energy storage in electric vehicles. A widespread adoption of EVs, however, requires [...] Read more.
The automotive industry is rapidly transitioning to electric vehicles (EVs) in response to the global efforts to reduce greenhouse gas emissions. Lithium-ion battery (LIB) has emerged as the main tool for energy storage in electric vehicles. A widespread adoption of EVs, however, requires a fast-charging technology that can significantly reduce charging time while avoiding any unsafe conditions including short circuits due to failure of the separator in an LIB cell. Therefore, it is necessary to understand the mechanical stresses during fast charging and their long-term effect on the integrity of the separator. This paper presents a novel hybrid model for the prediction of the stress distribution in the separator of a pouch cell under various charging speeds, ambient temperatures, and pack assembly conditions, such as compressive pressures. The proposed hybrid model consists of three sub-models, namely, an electrochemical cell model, a lumped-parameter model, and a solid mechanics model. A robust parameter identification scheme is implemented to determine the model parameters using the experimental data. The separator within the test setup will experience maximum von Mises stress of 74 MPa during 4C charging, i.e., when the charge current in A is four times as high as the capacity of the battery cell in Ah. To assess the evolution of the damage in the separator under the estimated stress during fast charging, creep and fatigue tests are conducted on the separator. Their results indicate a progressive accumulation of damage in the separator, further emphasizing the importance of understanding and mitigating mechanical degradation in separator materials. Full article
(This article belongs to the Special Issue Recent Progress of Battery Design, Modeling and Testing in Electric Vehicles)
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23 pages, 11376 KiB  
Article
A Coupled Nonlinear Viscoelastic–Viscoplastic Thermomechanical Model for Polymeric Lithium-Ion Battery Separators
by Royal Chibuzor Ihuaenyi, Jie Deng, Chulheung Bae and Xinran Xiao
Batteries 2023, 9(9), 475; https://doi.org/10.3390/batteries9090475 - 20 Sep 2023
Viewed by 1576
Abstract
One of the major concerns in ensuring lithium-ion battery (LIB) safety in abuse scenarios is the structural integrity of the battery separator. This paper presents a coupled viscoelastic–viscoplastic model for predicting the thermomechanical response of polymeric battery separators in abuse scenarios under combined [...] Read more.
One of the major concerns in ensuring lithium-ion battery (LIB) safety in abuse scenarios is the structural integrity of the battery separator. This paper presents a coupled viscoelastic–viscoplastic model for predicting the thermomechanical response of polymeric battery separators in abuse scenarios under combined mechanical and thermal loadings. The viscoplastic model is developed based on a rheological framework that considers the mechanisms involved in the initial yielding, change in viscosity, strain softening and strain hardening of polymeric separators. The viscoplastic model is then coupled with a previously developed orthotropic nonlinear thermoviscoelastic model to predict the thermomechanical response of polymeric separators before the onset of failure. The model parameters are determined for Celgard®2400, a polypropylene (PP) separator, and the model is implemented in the LS-DYNA® finite element (FE) package as a user-defined subroutine. Punch test simulations are employed to verify the model predictions under biaxial stress states. Simulations of uniaxial tensile stress–strain responses at different strain rates and temperatures are compared with experimental data to validate the model predictions. The model predictions of the material anisotropy, rate and temperature dependence agree well with experimental observations. Full article
(This article belongs to the Special Issue Recent Progress of Battery Design, Modeling and Testing in Electric Vehicles)
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15 pages, 5904 KiB  
Article
Intra-Layer Inhomogeneity of the Anode in Commercial Li-Ion Batteries
by Tuo Fang, Guangsen Jiang, Yong Xia and Pengfei Ying
Batteries 2023, 9(9), 463; https://doi.org/10.3390/batteries9090463 - 12 Sep 2023
Cited by 1 | Viewed by 1663
Abstract
The Li intercalation reaction exhibits non-uniform behavior along the thickness direction of the electrode in a Li-ion battery. This non-uniformity, or intra-layer inhomogeneity (ILIH), becomes more serious as the charging and discharging speed increases. Substantial ILIH can lead to Li plating and the [...] Read more.
The Li intercalation reaction exhibits non-uniform behavior along the thickness direction of the electrode in a Li-ion battery. This non-uniformity, or intra-layer inhomogeneity (ILIH), becomes more serious as the charging and discharging speed increases. Substantial ILIH can lead to Li plating and the emergence of inhomogeneous inner stress, resulting in a decrease in battery service life and an increase in battery safety risks. In this study, an operando optical observation was conducted based on the color change reaction during Li intercalation in the anode. Subsequently, we introduce a novel quantitative method to assess ILIH in commercial Li-ion batteries. A specific ILIH value (KILIH) is first used in this article for ILIH characterization. An analysis of KILIH at different charging and discharging rates was conducted, alongside the exploration of KILIH-SOC trends and their underlying mechanisms. The proposed method exhibits favorable mathematical convergence and physical interpretability, as supported by the results and mechanism analysis. By enabling the assessment of ILIH evolution in response to SOC and (dis)charging rate variations, the proposed method holds significant potential for optimizing fast charging protocols in commercial batteries and contributing to the development of refined electrochemical battery models in future research. Full article
(This article belongs to the Special Issue Recent Progress of Battery Design, Modeling and Testing in Electric Vehicles)
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13 pages, 1423 KiB  
Article
Experimental Application of the Global Technical Regulation on In-Vehicle Battery Durability
by Gian Luca Patrone and Elena Paffumi
Batteries 2023, 9(9), 454; https://doi.org/10.3390/batteries9090454 - 5 Sep 2023
Cited by 2 | Viewed by 2572
Abstract
Battery aging of electrified vehicles is a key parameter to be controlled in order to ensure sufficient energy efficiency and driving range across the whole vehicle lifespan. The United Nations Economic Commission for Europe has recently adopted a new regulatory framework, the Global [...] Read more.
Battery aging of electrified vehicles is a key parameter to be controlled in order to ensure sufficient energy efficiency and driving range across the whole vehicle lifespan. The United Nations Economic Commission for Europe has recently adopted a new regulatory framework, the Global Technical Regulation No. 22, prescribing minimum performance requirements for in-vehicle battery durability. With the implementation of this new GTR, monitors of the battery state of certified energy and range will be available in every production vehicle, the accuracy of which will be tested statistically by applying an in-use verification procedure (Part A). Once the monitors’ correctness is checked, the battery durability performances are controlled in Part B against the defined limit values by a fleet monitoring procedure. This work presents the results of a testing campaign executed at the Joint Research Centre testing facilities on an aged pure electric vehicle to measure its capacity and range fade. The aim is to explore the applicability of GTR No. 22, assessing the in-vehicle battery performance fade of an aged electric vehicle, illustrating the several steps of the developed regulation and experimental methodology. Full article
(This article belongs to the Special Issue Recent Progress of Battery Design, Modeling and Testing in Electric Vehicles)
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18 pages, 3073 KiB  
Article
Modeling of Lithium Plating and Stripping Dynamics during Fast Charging
by Polina Brodsky Ringler, Matthew Wise, Prashanth Ramesh, Jung Hyun Kim, Marcello Canova, Chulheung Bae, Jie Deng and Heechan Park
Batteries 2023, 9(7), 337; https://doi.org/10.3390/batteries9070337 - 21 Jun 2023
Cited by 6 | Viewed by 3551
Abstract
This paper proposes a new model that predicts the cell voltage dynamics and capacity degradation induced by lithium plating and stripping. The proposed model uses a single equilibrium reaction to describe the deposition and dissolution of metallic lithium, predicting the partial reversibility of [...] Read more.
This paper proposes a new model that predicts the cell voltage dynamics and capacity degradation induced by lithium plating and stripping. The proposed model uses a single equilibrium reaction to describe the deposition and dissolution of metallic lithium, predicting the partial reversibility of the plating/stripping reaction, the characteristic voltage plateau during relaxation, and the capacity loss due to the Loss of Cyclable Lithium (LCL). The model is integrated with a Doyle–Fuller–Newman (DFN) electrochemical model, calibrated and validated with experimental data. The model has the potential to improve the accuracy of predicting the effects of lithium plating in Li-ion cells and aid in the development of Extreme Fast Charging (XFC) technology for BEVs. Full article
(This article belongs to the Special Issue Recent Progress of Battery Design, Modeling and Testing in Electric Vehicles)
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19 pages, 4156 KiB  
Article
Influence of Cell Selection and Orientation within the Traction Battery on the Crash Safety of Electric-Powered Two-Wheelers
by Alessio Sevarin, Markus Fasching, Marco Raffler and Christian Ellersdorfer
Batteries 2023, 9(4), 195; https://doi.org/10.3390/batteries9040195 - 24 Mar 2023
Cited by 3 | Viewed by 2118
Abstract
The crash safety of lithium-ion traction batteries is a relevant concern for electric vehicles. Current passive safety strategies of traction batteries usually come at the cost of their volumetric or gravimetric energy density. This work analyses the influence of the variables cell selection [...] Read more.
The crash safety of lithium-ion traction batteries is a relevant concern for electric vehicles. Current passive safety strategies of traction batteries usually come at the cost of their volumetric or gravimetric energy density. This work analyses the influence of the variables cell selection and orientation within the traction battery on the crash safety of an electric-powered two-wheeler. These two variables do not negatively influence the traction battery’s volumetric or gravimetric energy density in the design process. Metamodels and numerical simulations are used to evaluate the crash safety of an electric-powered two-wheeler’s traction battery in a potentially dangerous crash scenario. The influence of the variable’s cell selection and orientation is evaluated through the internal short circuit risk of the integrated cells. The comparison of the metamodels shows that the cell orientation reduces the internal short circuit risk by up to 51% on average in the analysed crash scenario. The cell selection reduces it only up to 21% on average. The results show that crash safety can be increased in the design process, and a combination with the current protection strategies can increase crash safety further. Full article
(This article belongs to the Special Issue Recent Progress of Battery Design, Modeling and Testing in Electric Vehicles)
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