Comprehensive mechanical characterization of prismatic lithium-ion cells

As electric vehicles (EVs) become increasingly prevalent, ensuring the safety of their battery systems is paramount. Lithium-ion batteries, the cornerstone of modern EV technology, present unique safety challenges due to their high energy density and the potential for catastrophic failure under certain conditions. The importance of understanding and mitigating these risks cannot be overstated, particularly as the industry strives to meet growing global demand while adhering to stringent safety standards. Battery safety is not just a technical concern but a critical factor in public acceptance and the widespread adoption of EVs. This study presents an extensive series of experimental tests conducted on prismatic cells from two different manufacturers. These tests include flat punch, hemispherical punch, and three-point bending tests, all designed to assess the cells’ structural integrity and failure modes. Key areas of interest include the behavior of the cell casing, jellyroll, and critical components under varying loading conditions. The experimental results provide valuable insights into the mechanical performance of these cells, and while this paper focuses primarily on the testing methodologies and initial findings, future work will incorporate these experimental results into detailed finite element models for further analysis. A model was developed simulating the behavior of the cell under various loading scenarios. These findings underscore the need for continuous research and development to address emerging safety challenges as EV technology evolves. Ultimately, advancing our knowledge of battery safety is crucial for ensuring the reliability and trustworthiness of EVs in real-world scenarios, thereby fostering greater consumer confidence in this transformative technology.