Homogenized characterization of cylindrical Li‐ion battery cells using elliptical approximation

Homogenization and finding the constitutive model of jellyroll in cylindrical lithium-ion batteries can be challenging because of their form factor. Taking samples out of the original jellyroll wounding or compressing cell assembly in its cylindrical coordinates are two possibilities for measuring the homogenized lateral strength of the cell. However, the former causes loss of accuracy due to changing constraints and electrolyte environment, and the latter requires complex fixtures that are not readily available or even practical to manufacture. Various approaches have been suggested by researchers to circumvent the above difficulties and allow the extraction of hardening curves. However, the precision of those approaches diminishes when the cells are under global compression vs local punch deformations. In this study, an updated homogenization method is established, using a lateral compression test on the jellyroll. The homogenization method is based on the assumption that the circular cross-section of the jellyroll under compression is deformed in an elliptical shape. Then the principle of virtual work is used to extract the hardening curve. To validate the above characterization model, isotropic and anisotropic finite element models were developed using crushable foam and modified honeycomb material models from the LS-DYNA library. Four sets of cell-level experiments were performed on cylindrical batteries using custom-designed fixtures, including flat lateral compression, rod indentation, hemispherical punch, and three-point bending. The voltage and surface temperature of the batteries were measured to capture the onset of short circuit during the tests. Comparison of the simulation results confirmed that the proposed homogenization method and the FE models can predict the behavior of cylindrical lithium-ion batteries with much higher accuracy compared to the currently available methods presented in the literature.