Thermal Modeling of Li-Ion Cylindrical Cells at Scale

Abstract

The electric vehicle industry has created a demand for batteries with higher power densities. The current design choice for low-weight lithium-ion battery packs for electric vehicles is to create stacks arranged in parallel or series configurations to match the power demands. The individual cells are separated and placed in a cooling duct to pull heat away from the longitudinal surface convective. The amount of cooling is dependent on the internal temperature of batteries core. The current design of the cylindrical cell is to roll the cathode, anode, and separators into a jelly roll together and attach a tab to the cathode and anode at opposite corners of the sheet. The tabs connect to the positive and negative terminals of the cell to draw current away from the cell. The tabs may act as an agent for drawing heat away from the center of the battery. Currently, commonly used cylindrical cells have a form factor of 18650, 21700, or 26650. The thermal, geometrical, and electrical properties of 18650 and 21700 cylindrical cells are studied and it is found that the 21700 cells showed additional degradation and stronger heating. Recently, companies like Tesla have produced cylindrical cells with a 4680-form factor, which is a decent way to increase the ratio of active material vs. inactive material in a cylindrical cell. However, large diameter thick cylindrical cells suffer from thermal issues. Even large format pouch cells suffer through heat trapped within the stack.Since the thermal conductivity of the anode and cathode electrodes is often near 1 W/m-K, it becomes difficult for the heat to be extracted from the center of a large-diameter cylindrical cell without forming a considerable thermal gradient. PyBaMM, an open-source mathematical modeling software written in Python programming language, has the capability to simulate different electrochemical models such as the Doyle-Fuller-Newman (DFN), Single particle model (SPM), and SPMe, and varying chemistry. The software provides easy access to the cell parameters modification and graphical user interface capabilities. The PyBaMM framework also allows to simulation lumped, isothermal, and base thermal models which are electrochemically coupled. PyBaMM uses CasADi (computer algebra systems algorithmic differentiation). The thermal gradient and heat dynamics within a porous electrode are modeled using PoreSpy and openpnm, two open-source Python libraries used to design porous networks and model physical equations such as governing heat flow, concentration gradient, and movement of water/oil through porous shale media.We have explored and combined heat dynamic models for Li-Ion cylindrical cells at both cell and electrode levels with reduced-order Doyle-Fuller-Newman electro-chemical model frameworks implemented in the PyBaMM python library. Radial temperature gradient at cell and electrode levels were both generated from simulations with a distributed parameter model as a function of electrolyte and separator thickness and thermodynamic properties. Figure 1