Structural analysis and experimental characterization of cylindrical lithium-ion battery cells subject to lateral impact

We report on modeling mechanical response of cylindrical lithium-ion battery cells that are commonly used in automotive applications when subjected to impact testing. The developed homogenized model that accurately captures mechanical response of a cell to lateral crash is reported. The proposed model was validated using static and dynamic experimental testing. Highly nonlinear mechanical deformations of the cells were captured experimentally using a high-speed camera and later characterized through computer tomography. Numerically, we have investigated the feasibility of using explicit finite element code for accurate modeling of impact on one cell, so it can be used for an entire battery pack that consists of hundreds or thousands of cells. In this study, we have developed and compared two homogenization methods for the jellyroll in a cylindrical lithium-ion battery cell. Homogenization was conducted in a lateral/radial direction. Based on the results of the homogenization, the material model utilizing crushable foam constitutive behavior was then developed for simulations. Experimental results showed a very good agreement with simulations, thus validating the proposed approach and giving us confidence to move forward with the crush simulations of an entire battery pack. Zones of potential electric shortages were determined based on the experiments and simulations.