Insight into the deformation features and capacity loss mechanisms of lithium-ion pouch cells under spherical indentation conditions

Zhu, Xiaoqing; Wang, Yuxuan; Wang, Hsin; Cakmak, Ercan; Ju, Xing; Lu, Xue-wei

doi:10.1016/j.jpowsour.2025.237287

Insight into the deformation features and capacity loss mechanisms of lithium-ion pouch cells under spherical indentation conditions

Journal Article · Sat May 10 00:00:00 EDT 2025 · Journal of Power Sources

DOI:https://doi.org/10.1016/j.jpowsour.2025.237287· OSTI ID:2573168

^[1]; ^[2]; ^[3]; ^[3]; Ju, Xing ^[2]; Lu, Xue-wei ^[2]

North China Electric Power University, Beijing (China); Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States); Beijing Institute of Technology (China)
North China Electric Power University, Beijing (China)
Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Mechanical deformation under extreme conditions is one of the important reasons for the failure of lithium-ion batteries in automotive application. However, the deformation features and component failure of lithium-ion cells to external loading has never been a design consideration. Here, in this study, we conduct spherical indentation tests on a dozen of lithium-ion cells with different capacities under different control mode conditions to investigate their deformation features and capacity loss mechanisms. The experimental results show that, under mechanical deformation conditions, internal faults of cells occur in stages, and energy accumulation and sudden release are two key processes of cell's mechanical failure. The cells' state of charge is the main factor affecting their thermal runaway behaviors. In addition, a finite element model is developed to simulate the deformation features and the failure mechanism of key components of lithium-ion pouch cells; the 3D x-ray computed tomography is employed to demonstrate its internal configuration. With this model, the force-strain response, the deformation features as well as the size of the failure area of lithium-ion cells under spherical indentation conditions are accurately predicted. In 3D x-ray computed tomography images, unique mud cracks in cooper current collector are observed, and the influence mechanisms of the isolated fragments on the cell capacities are revealed. These results may provide useful information for the mechanical structure design of the components of lithium-ion pouch cells.

View Accepted Manuscript (DOE)

Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE Office of Electricity (OE); Beijing Natural Science Foundation; Fundamental Research Funds for the Central Universities

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 2573168

Journal Information:: Journal of Power Sources, Journal Name: Journal of Power Sources Vol. 646; ISSN 0378-7753

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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Capacity loss mechanisms
Deformation
FE simulation
Lithium-ion pouch cell
Spherical indentation

Insight into the deformation features and capacity loss mechanisms of lithium-ion pouch cells under spherical indentation conditions

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