Flexible Sensing for Precise Lithium-Ion Battery Swelling Monitoring: Mechanisms, Integration Strategies, and Outlook

The expansion force generated by lithium-ion batteries during charge-discharge cycles is a key indicator of their structural safety and health. Recently, flexible pressure-sensing technologies have emerged as promising solutions for in situ swelling monitoring, owing to their high flexibility, sensitivity and integration capability. This review provides a systematic summary of progress in this field. Firstly, we discuss the mechanisms of battery swelling and the principles of conventional measurement methods. It then compares their accuracy, dynamic response and environmental adaptability. Subsequently, the main flexible pressure-sensing mechanisms are categorized, including piezoresistive, capacitive, piezoelectric and triboelectric types, and their material designs, structural configurations and sensing behaviors are discussed. Building on this, we examine integration strategies for flexible pressure sensors in battery systems. It covers surface-mounted and embedded approaches at the cell level, as well as array-based and distributed schemes at the module level. A comparative analysis highlights the differences in installation constraints and monitoring capabilities between these approaches. Additionally, this section also summarizes the characteristics of swelling signals and recent advances in data processing techniques, including AI-assisted feature extraction, fault detection and health state correlation. Despite their promise, challenges such as long-term material stability and signal interference remain. Future research is expected to focus on high-performance sensing materials, multimodal sensing fusion and intelligent data processing, with the aim of further advancing the integration of flexible sensing technologies into battery management systems and enhancing early warning and safety protection capabilities.