Multi-objective optimization of lithium-ion battery designs considering the dilemma between energy density and rate capability

• A multi-objective optimization framework is proposed to achieve optimal battery design with a balanced performance. • Elevating operating temperature can achieve high energy density and rate capability simultaneously. • A combined optimization of design parameters and temperature renders a ultralong EV lifespan of 148,000 km. Electrified transportation requires batteries with high energy density and high-rate capability for both charging and discharging. Li-ion batteries (LiBs) face a dilemma: increasing areal capacity and reducing electrode porosity to boost energy density often reduces rate capability due to a longer and more tortuous ion transfer path. Tailoring cell design parameters to balance these metrics is essential but challenging. Here, we present a multi-objective optimization framework targeting energy density, fast charging, high-rate discharging, and lifespan simultaneously. Four cell parameters—cathode areal capacity, N-P ratio, cathode porosity, and anode porosity—along with operating temperature, are selected as design variables. A physics-based pseudo-2D model, validated against experimental data, generates data to train the surrogate model, which is combined with the NSGA-II algorithm for rapid optimization. Three different objective calculation methods are compared to identify the maximum sum of energy densities, lowest polarization, and most balanced performance, respectively. Cell design parameters are optimized at different temperatures using the most balanced optimization method. Results demonstrate that elevating cell operating temperature achieves high-rate capability while maintaining high energy density, mitigating the energy-power trade-off and broadening battery design parameter ranges.