Analysis of thermal management and anti-mechanical abuse of multi-functional battery modules based on magneto-sensitive shear thickening fluid

Electric vehicles(EVs)have garnered significant attention as a vital driver of economic growth and environmental sustainability.Nevertheless,ensuring the safety of high-energy batteries is now a top priority that cannot be overlooked during large-scale applications.This paper proposes an innovative active protection and cooling integrated battery module using smart materials,magneto-sensitive shear thickening fluid(MSTF),which is specifically designed to address safety threats posed by lithium-ion batteries(LIBs)exposed to harsh mechanical and environmental conditions.The theoretical framework introduces a novel approach for harnessing the smoothed-particle hydrodynamics(SPH)methodology that incorporates the intricate interplay of non-Newtonian fluid behavior,capturing the fluid-structure coupling inherent to the MSTF.This approach is further advanced by adopting an enhanced Herschel-Bulkley(H-B)model to encapsulate the intricate rheology of the MSTF under the influence of the magnetorheological effect(MRE)and shear thickening(ST)behavior.Numerical simulation results show that in the case of cooling,the MSTF is an effective cooling medium for rapidly reducing the temperature.In terms of mechanical abuse,the MSTF solidifies through actively applying the magnetic field during mechanical compression and impact within the battery module,resulting in 66%and 61.7%reductions in the maximum stress within the battery jellyroll,and 31.1%and 23%reductions in the reaction force,respectively.This mechanism effectively lowers the risk of short-circuit failure.The groundbreaking concepts unveiled in this paper for active protection battery modules are anticipated to be a valuable technological breakthrough in the areas of EV safety and lightweight/integrated design.

A pre-strain strategy of current collectors for suppressing electrode debonding in lithium-ion batteries

The interfacial debonding between the active layer and the current collector has been recognized as a critical mechanism for battery fading,and thus has attracted great efforts focused on the related analyses.However,much still remains to be studied regarding practical methods for suppressing electrode debonding,especially from the perspective of mechanics.In this paper,a pre-strain strategy of current collectors to alleviate electrode debonding is proposed.An analytical model for a symmetric electrode with a deformable and limited-thickness current collector is developed to analyze the debonding behavior involving both a pre-strain of the current collector and an eigen-strain of the active layers.The results reveal that the well-designed pre-strain can significantly delay the debonding onset(by up to 100%)and considerably reduce the debonding size.The critical values of the pre-strain are identified,and the pre-strain design principles are also provided.Based on these findings,this work sheds light on the mechanical design to suppress electrode degradation.

Effects of stress dependent electrochemical reaction on voltage hysteresis of lithium ion batteries

Intercalation of lithium ions into the electrodes of lithium ion batteries is affected by the stress of active materials, leading to energy dissipation and stress dependent voltage hysteresis. A reaction-diffusion-stress coupling model is established to investigate the stress effects under galvanostatic and potentiostatic operations. It is found from simulations that the stress hysteresis contributes to the voltage hysteresis and leads to the energy dissipation. In addition, the stress induced voltage hysteresis is small in low rate galvanostatic operations but extraordinarily significant in high rate cases. In potentiostatic operations, the stresses and stress induced overpotentials increase to a peak value very soon after the operation commences and decays all the left time. Therefore,a combined charge-discharge operation is suggested, i.e., first the galvanostatic one and then the potentiostatic one. This combined operation can not only avoid the extreme stress during operations so as to prevent electrodes from failure but also reduce the voltage hysteresis and energy dissipation due to stress effects.

Two-way coupled analysis of lithium diffusion and diffusion induced finite elastoplastic bending of bilayer electrodes in lithium-ion batteries

A fully coupling model for the diffusion induced finite elastoplastic bending of bilayer electrodes in lithium-ion batteries is proposed. The effect of the mechanical stress on the lithium diffusion is accounted for by the mechanical part of the chemical potential derived from the Gibbs free energy along with the logarithmic stress and strain. Eight dimensionless parameters, governing the stress-assisted diffusion and the diffusion induced elastoplastic bending, are identified. It is found that the finite plasticity starting from the interface of the bilayer increases the chemical potential gradient and thereby facilitates the lithium diffusion. The full plastic flow makes the abnormal lithium concentration distribution possible, i.e., the concentration at the lithium inlet can be lower than the concentration at the interface(downstream). The increase in the thickness of the active layer during charging is much larger than the eigen-stretch due to lithiation, and this excess thickening is found to be caused by the lithiation induced plastic yield.

Analysis of diffusion induced elastoplastic bending of bilayer lithium-ion battery electrodes

Bilayer electrode, composed of a current collector layer and an active material layer, has great potential in applications of in-situ electrochemical experiments due to the bending upon lithiation. This paper establishes an elastoplastic theory for the lithiation induced deformation of bilayer electrode with consideration of the plastic yield of current collector. It is found that the plastic yield of current collector reduces the restriction of current collector to an active layer, and therefore, enhances in-plane stretching while lowers down the rate of electrode bending. Key parameters that influence the elastoplastic deformation are identified. It is found that the smaller thickness ratio and lower elastic modulus ratio of current collector to an active layer would lead to an earlier plastic yield of the current collector, the larger in-plane strain, and the smaller bending curvature, due to balance between the current collector and the active layer. The smaller yield stress and plastic modulus of current collector have similar impacts on the electrode deformation.

Prelithiation design for suppressing delamination in lithium-ion battery electrodes

Prelithiation has been intensively investigated in high-capacity lithiumion batteries(LIBs).However,the optimization of prelithiation degrees for long service life of LIBs still remains a challenge.The positive effect of prelithiation on suppressing degradation of LIBs,besides directly pursuing the high first Coulomb efficiency which has been widely reported in the literature,is revealed and discussed based on an analytical model focusing on the interfacial delamination in electrodes.For full charge-discharge cycling,well-designed prelithiation can effectively suppress the delamination and reduce the debonding size by approximately 25%,compared with the case without prelithiation.For the strategy combining partial charge-discharge cycling and prelithiation,the largest reversible capacity without debonding can be significantly improved by approximately100%with well-designed prelithiation.This work is expected to provide a prelithiation design principle and further improve the mechanical stability of LIB electrodes.

A modified pulse charging method for lithium-ion batteries by considering stress evolution,charging time and capacity utilization

The stress evolution, total charging time and capacity utilization of pulse charging (PC) method are investigated in this pape匚 It is found that compared to the conventional constant current (CC) charging method, the PC method can accelerate the charging process but will inevitably cause an increase in stress and a decrease in capacity. The charging speed for PC method can be estimated by the mean current. By introducing stress control, a modified PC method called the PCCC method, which starts with a PC operation followed by a CC operation, is proposed. The PCCC method not only can accelerate charging process but also can avoid the stress raising and capacity loss occurring in the PC method. Furthermore, the optimal pulsed current density and switch time in the PCCC method is also discussed.

Understanding Modulus Variation of the Active Layers of Silicon Composite Electrodes

The variation of the effective modulus of silicon composite electrodes,which is a fundamental feature to analyze the coupled mechanical–electrochemical behavior of Si-based electrodes in high-capacity lithium-ion batteries,remains qualitatively controversial.To clarify the contradictory experimental results,numerical modeling of a representative volume element with silicon particles,carbon-binder domains(CBDs),and pores has been performed for the lithiation process.The key parameters for modulus variation were identified and evaluated.A mesostructure change is proposed to be a crucial mechanism that affects the modulus variation,and silicon softening is another key mechanism.Silicon softening and the decreasing CBD volume fraction collectively result in a decrease in the effective modulus of the composite,whereas an increase in the silicon volume fraction along with a decrease in porosity has the opposite effect.The findings of this work provide an in-depth and fundamental understanding of the mechanical properties of silicon composite electrodes.