Thermal–Electrical Optimization of Lithium-Ion Battery Conductor Structures Under Extreme High Amperage Current
This study addresses the critical challenges of conductor structure fusing, thermal management failure, and thermal runaway risks in lithium-ion batteries under extreme high-amperage discharge conditions. By integrating theoretical analysis, multiphysics coupling simulations, and experimental valida...
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MDPI AG
2025-05-01
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| Online Access: | https://www.mdpi.com/2076-3417/15/10/5338 |
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| author | Jingdi Guo Yiran Wang He Liu Yahui Liu Xiaokang Yang |
| author_facet | Jingdi Guo Yiran Wang He Liu Yahui Liu Xiaokang Yang |
| author_sort | Jingdi Guo |
| collection | DOAJ |
| description | This study addresses the critical challenges of conductor structure fusing, thermal management failure, and thermal runaway risks in lithium-ion batteries under extreme high-amperage discharge conditions. By integrating theoretical analysis, multiphysics coupling simulations, and experimental validation, the research systematically investigates the overcurrent capability of lithium battery conductor structures. A novel current–thermal structure coupled finite element model was developed to analyze the dynamic relationship between key parameters, specifically overcurrent cross-sectional area and contact area, and their influence on temperature gradient distribution. Experimental results confirm the model’s accuracy, revealing that under extreme high-amperage conditions, increasing the conductor cross-sectional area by 50% only marginally extends the battery’s current-carrying duration from 0.75 s to 0.8 s. This limited enhancement is attributed to rapid heat generation, which restricts the effectiveness of increasing the cross-sectional area alone. Instead, optimizing the conductor structure by modifying the heat conduction path, which involves a similar increase in the cross-sectional area and an additional 60% increase in contact area through the addition of a welding reinforcement structure, achieves thermal equilibrium. The optimized design achieves a current-carrying duration of 1.73 s, which is 230% of the duration of the traditional configuration. This work establishes a scalable framework for enhancing the thermal–electrical performance of lithium-ion batteries, providing a theoretical foundation for structural optimization and offering significant methodological support for advancing research in high-power battery design, with potential applications in electric vehicles, renewable energy systems, and industrial robotics. |
| format | Article |
| id | doaj-art-0bc8d0fd7fd842d7b4398a0f14fc3105 |
| institution | DOAJ |
| issn | 2076-3417 |
| language | English |
| publishDate | 2025-05-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Applied Sciences |
| spelling | doaj-art-0bc8d0fd7fd842d7b4398a0f14fc31052025-08-20T03:14:45ZengMDPI AGApplied Sciences2076-34172025-05-011510533810.3390/app15105338Thermal–Electrical Optimization of Lithium-Ion Battery Conductor Structures Under Extreme High Amperage CurrentJingdi Guo0Yiran Wang1He Liu2Yahui Liu3Xiaokang Yang4China Lithium Battery Technology (Luoyang) Co., Ltd., Luoyang 471003, ChinaSchool of Vehicle and Transportation Engineering, Henan University of Science and Technology, Luoyang 471003, ChinaSchool of Mechatronics Engineering, Henan University of Science and Technology, Luoyang 471003, ChinaSchool of Mechatronics Engineering, Henan University of Science and Technology, Luoyang 471003, ChinaSchool of Mechatronics Engineering, Henan University of Science and Technology, Luoyang 471003, ChinaThis study addresses the critical challenges of conductor structure fusing, thermal management failure, and thermal runaway risks in lithium-ion batteries under extreme high-amperage discharge conditions. By integrating theoretical analysis, multiphysics coupling simulations, and experimental validation, the research systematically investigates the overcurrent capability of lithium battery conductor structures. A novel current–thermal structure coupled finite element model was developed to analyze the dynamic relationship between key parameters, specifically overcurrent cross-sectional area and contact area, and their influence on temperature gradient distribution. Experimental results confirm the model’s accuracy, revealing that under extreme high-amperage conditions, increasing the conductor cross-sectional area by 50% only marginally extends the battery’s current-carrying duration from 0.75 s to 0.8 s. This limited enhancement is attributed to rapid heat generation, which restricts the effectiveness of increasing the cross-sectional area alone. Instead, optimizing the conductor structure by modifying the heat conduction path, which involves a similar increase in the cross-sectional area and an additional 60% increase in contact area through the addition of a welding reinforcement structure, achieves thermal equilibrium. The optimized design achieves a current-carrying duration of 1.73 s, which is 230% of the duration of the traditional configuration. This work establishes a scalable framework for enhancing the thermal–electrical performance of lithium-ion batteries, providing a theoretical foundation for structural optimization and offering significant methodological support for advancing research in high-power battery design, with potential applications in electric vehicles, renewable energy systems, and industrial robotics.https://www.mdpi.com/2076-3417/15/10/5338lithium-ion batteryconductor structurehigh-amperage currentovercurrent capabilitythermal equilibrium |
| spellingShingle | Jingdi Guo Yiran Wang He Liu Yahui Liu Xiaokang Yang Thermal–Electrical Optimization of Lithium-Ion Battery Conductor Structures Under Extreme High Amperage Current Applied Sciences lithium-ion battery conductor structure high-amperage current overcurrent capability thermal equilibrium |
| title | Thermal–Electrical Optimization of Lithium-Ion Battery Conductor Structures Under Extreme High Amperage Current |
| title_full | Thermal–Electrical Optimization of Lithium-Ion Battery Conductor Structures Under Extreme High Amperage Current |
| title_fullStr | Thermal–Electrical Optimization of Lithium-Ion Battery Conductor Structures Under Extreme High Amperage Current |
| title_full_unstemmed | Thermal–Electrical Optimization of Lithium-Ion Battery Conductor Structures Under Extreme High Amperage Current |
| title_short | Thermal–Electrical Optimization of Lithium-Ion Battery Conductor Structures Under Extreme High Amperage Current |
| title_sort | thermal electrical optimization of lithium ion battery conductor structures under extreme high amperage current |
| topic | lithium-ion battery conductor structure high-amperage current overcurrent capability thermal equilibrium |
| url | https://www.mdpi.com/2076-3417/15/10/5338 |
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