Impact of different thermal gradients on the dynamics of cylindrical lithium-ion cells subject to accelerated aging and on module performance

• Published in: Applied thermal engineering Vol. 274; p. 126639
• Main Authors: Effat, Mohammed B., Kubal, Joseph J., Knehr, Kevin W., Ahmed, Shabbir
• Format: Journal Article
• Language: English
• Published: Elsevier Ltd 01.09.2025
• Subjects: Battery thermal management; Cell degradation; Current dynamics; Module lifetime; NCA-graphite; Battery thermal management; Module lifetime; Current dynamics; NCA-graphite; Cell degradation
• ISSN: 1359-4311
• DOI: 10.1016/j.applthermaleng.2025.126639

•CFD and P2D models link thermal gradients to variability in module performance.•Cooling plate designs influence current and voltage imbalances among cells in modules.•The orientation of thermal gradients and electrical connectivity is critical for design. This study investigates the impacts of applying different thermal gradient patterns to cylindrical lithium-ion cells in a module on cell dynamics (temperatures, current flows, state of charge), module performance (evolution of resistance, capacity, and energy versus cycle number), and module lifetime. The thermal gradients were generated using cooling plates (CPs) with three different flow-field designs, namely, straight, perpendicular, and U-turn. The study uses computational fluid dynamics (CFD), the pseudo-two-dimensional (P2D) battery model, capacity loss and increased impedance due to the growth of a solid-electrolyte-interphase, and the electric current distribution from module terminals to cells that depends on the series–parallel electrical connections among the cells. The impact of the thermal gradient (resulting from the CP designs) on the variability in resistance, current, state of charge, and voltage among the cells was analyzed and linked to differences in the module’s performance. Applying a thermal gradient to parallel-connected strings of series-connected cells led to variation in the current through each parallel string and animbalance in the voltage of series-connected cells. Module performance is poorer when the thermal gradient causes a voltage imbalance than when it causes a current imbalance. Module performance becomes the worst when both current variation and voltage imbalance happen together. For instance, the module’s lifetime (estimated as reaching 80% of its initial capacity) varied by 5% to 17.5%, depending on the magnitude and pattern of the imposed thermal gradient. As the relative orientation between thermal gradients and cells’ electrical connectivity influences the module’s performance, appropriate consideration should be given to the choice of the CP, especially if large thermal gradients are allowed.