Batteries, Volume 6, Issue 3 (September 2020) – 13 articles

Ensuring the precision and repeatability of component assembly in the production of electric vehicle (EV) battery modules requires fast and accurate measuring methods. The durability of EV battery packs depends on the quality of welded connections, therefore exact positioning of the module components is critical for ensuring safety in exploitation. Laser welding is a non-contact process capable of welding dissimilar materials with high precision, for that reason it has become the preferred joining method in battery production. In high volume manufacturing, one of the main production challenges is reducing the time required for assessment of dimensional and geometrical accuracy prior to joining. This paper reviews the challenges of EV battery design and manufacturing and discusses commercially available scanner-based measurement systems suitable for fabrication of battery pack components. Versatility of novel metrological systems creates new opportunities for increasing the production speed, quality and safety of EV battery modules. Full article

The development of long lifetime Li–S batteries requires new sulfur–carbon based composite materials that are able to suppress the shuttle effect—namely, the migration of soluble lithium polysulfides from the cathode to the anode of the cell. Graphene is one of the most promising carbon supports for sulfur, thanks to its excellent conductivity and to the possibility of tailoring its chemical–physical properties, introducing heteroatoms in its structure. By using first principle density functional theory simulations, this work aims at studying the effect of doping graphene with group III elements (B, Al, Ga) on its electronic properties and on its chemical affinity towards lithium polysulfides. Our results show that Al and Ga doping strongly modify the local structure of the lattice near heteroatom site and generate a charge transfer between the dopant and its nearest neighbor carbon atoms. This effect makes the substrate more polar and greatly enhances the adsorption energy of polysulfides. Our results suggest that Al- and Ga-doped graphene could be used to prepare cathodes for Li–S cells with improved performances and lifetime. Full article

Currently, apart from the widely known lithium-ion batteries, there are competitive solutions in the form of, for example, Li-S batteries. While the results of studies on the toxicity of Li-ion battery components are published, such studies on the components of Li-S cells are just beginning. The purpose of the current review was to identify materials used in the production of Li-S batteries and their toxicity, especially for humans. The review showed many kinds of materials with different levels of toxicity utilized for manufacturing of these cells. Some materials are of low toxicity, while some others are of the high one. A lot of materials have assigned different hazard statements. For some of the materials, no hazard statements were assigned, although such materials are toxic. No data related to the toxicity of some materials were found in the literature. This points out the need to further studies on their toxicity and legal actions to assign appropriate hazard statements. Full article

Lithium (Li)-ion battery thermal management systems play an important role in electric vehicles because the performance and lifespan of the batteries are affected by the battery temperature. This study proposes a framework to establish equivalent circuit models (ECMs) that can reproduce the multi-physics phenomenon of Li-ion battery packs, which includes liquid cooling systems with a unified method. We also demonstrate its utility by establishing an ECM of the thermal management systems of the actual battery packs. Experiments simulating the liquid cooling of a battery pack are performed, and a three-dimensional (3D) model is established. The 3D model reproduces the heat generated by the battery and the heat transfer to the coolant. The results of the 3D model agree well with the experimental data. Further, the relationship between the flow rate and pressure drop or between the flow rate and heat transfer coefficients is predicted with the 3D model, and the data are used for the ECM, which is established using MATLAB Simulink. This investigation confirmed that the ECM’s accuracy is as high as the 3D model even though its computational costs are 96% lower than the 3D model. Full article

Several new compounds, with desirable properties of ion mobility and working voltage, have been recently proposed using a density functional theory (DFT) computational approach as potential electrode materials for beyond-lithium battery systems. After evaluation of the ‘energy above hull’, thiospinel MgCr₂S₄ has been suggested as interesting multivalent battery cathode candidate, even though the synthesis of its exact stoichiometry poses serious challenges. In this work, MgCr₂S₄ is prepared using an innovative mechanochemical route starting from magnesium or magnesium hydride, chromium, and sulfur powders. The progress of such mechanically induced reaction as a function of processing time is carefully monitored by XRD with Rietveld refinement, evidencing the occurrence of a mechanically induced self-propagating reaction (MSR). The effect of parameters associated with the milling apparatus (impact energy) on the products composition are also investigated. To our knowledge, this work represents the first report of the scalable and simple mechanical alloying synthesis of thiospinel MgCr₂S₄ (space group Fd-3 m, a = 10.09 Å) and opens up interesting possibilities for the exploitation of such material in next-generation post-lithium batteries. Full article

Battery state of charge (SOC) accuracy plays a vital role in a hybrid electric vehicle (HEV), as it ensures battery safety in a harsh operating environment, prolongs life, lowers the cost of energy consumption, and improves driving mileage. Therefore, accurate SOC battery estimation is the central idea of the approach in this research, which is of great interest to readers and increases the value of its application. Moreover, an accurate SOC battery estimate relies on the accuracy of the battery model parameters and its capacity. Thus, the purpose of this paper is to design, implement and analyze the SOC estimation accuracy of two battery models, which capture the dynamics of a rechargeable SAFT Li-ion battery. The first is a resistor capacitor (RC) equivalent circuit model, and the second is a generic Simscape model. The model validation is based on the generation and evaluation of the SOC residual error. The SOC reference value required for the calculation of residual errors is the value estimated by an ADVISOR 3.2 simulator, one of the software tools most used in automotive applications. Both battery models are of real interest as a valuable support for SOC battery estimation by using three model based Kalman state estimators developed in Part 2. MATLAB simulations results prove the effectiveness of both models and reveal an excellent accuracy. Full article

The purpose of this paper is to analyze the accuracy of three state of charge (SOC) estimators of a rechargeable Li-ion SAFT battery based on two accurate Li-ion battery models, namely a linear RC equivalent electrical circuit (ECM) and a nonlinear Simscape generic model, developed in Part 1. The battery SOC of both Li-ion battery models is estimated using a linearized adaptive extended Kalman filter (AEKF), a nonlinear adaptive unscented Kalman filter (AUKF) and a nonlinear and non-Gaussian particle filter estimator (PFE). The result of MATLAB simulations shows the efficiency of all three SOC estimators, especially AEKF, followed in order of decreasing performance by AUKF and PFE. Besides, this result reveals a slight superiority of the SOC estimation accuracy when using the Simscape model for SOC estimator design. Overall, the performance of all three SOC estimators in terms of accuracy, convergence of response speed and robustness is excellent and is comparable to state of the art SOC estimation methods. Full article

Temperature prediction of a battery plays a significant role in terms of energy efficiency and safety of electric vehicles, as well as several kinds of electric and electronic devices. In this regard, it is crucial to identify an adequate model to study the thermal behavior of a battery. This article reports a comparative study on thermal modeling approaches by using a ${\mathrm{LiCoO}}_2$ 26650 lithium-ion battery, and provides a methodology to characterize electrothermal phenomena. Three approaches have been implemented numerically—a thermal lumped model, a 3D computational fluid dynamics model, and an electrochemical model based on Newman, Tiedemann, Gu and Kim formulation. The last two methods were solved using ANSYS Fluent software. Simulations were validated with experimental measurements of the cell surface temperature at constant current discharge and under a highway driving cycle. Results show that the three models are consistent with actual temperature measurements. The electrochemical method has the lower error at 0.5C. Nevertheless, this model provides the higher error ( $1.3$${}^{\circ }\mathrm{C}$) at 1.5C, where the maximum temperature increase of the cell was $18.1$${}^{\circ }\mathrm{C}$. Under the driving cycle, all the models are in the same order of error. Lumped model is suitable to simulate a wide range of battery operating conditions. Furthermore, this work was expanded to study heat generation, voltage and heat transfer coefficient under natural convection. Full article

The economic value of high-capacity battery systems, being used in a wide variety of automotive and energy storage applications, is strongly affected by the duration of their service lifetime. Because many battery systems now feature a very large number of individual cells, it is necessary to understand how cell-to-cell interactions can affect durability, and how to best replace poorly performing cells to extend the lifetime of the entire battery pack. This paper first examines the baseline results of aging individual cells, then aging of cells in a representative 3S3P battery pack, and compares them to the results of repaired packs. The baseline results indicate nearly the same rate of capacity fade for single cells and those aged in a pack; however, the capacity variation due to a few degrees changes in room temperature (≃±3 ${}^{\circ }$ C) is significant (≃±1.5% of capacity of new cell) compared to the percent change of capacity over the battery life cycle in primary applications (≃20–30%). The cell replacement strategies investigation considers two scenarios: early life failure, where one cell in a pack fails prematurely, and building a pack from used cells for less demanding applications. Early life failure replacement found that, despite mismatches in impedance and capacity, a new cell can perform adequately within a pack of moderately aged cells. The second scenario for reuse of lithium ion battery packs examines the problem of assembling a pack for less-demanding applications from a set of aged cells, which exhibit more variation in capacity and impedance than their new counterparts. The cells used in the aging comparison part of the study were deeply discharged, recovered, assembled in a new pack, and cycled. We discuss the criteria for selecting the aged cells for building a secondary pack and compare the performance and coulombic efficiency of the secondary pack to the pack built from new cells and the repaired pack. The pack that employed aged cells performed well, but its efficiency was reduced. Full article

Common issues aqueous-based vanadium redox flow batteries (VRFBs) face include low cell voltage due to water electrolysis side reactions and highly corrosive and environmentally unfriendly electrolytes (3 to 5 M sulfuric acid). Therefore, this investigation looks into the comparison of a highly conductive ionic liquid with a well-studied deep eutectic solvent (DES) as electrolytes for non-aqueous VRFBs. The latter solvent gives 50% higher efficiency and capacity utilization than the former. These figures of merit increase by 10% when nitrogen-doped graphene (N-G)-modified carbon papers, via a one-step binder-free electrophoretic deposition process, are used as electrodes. X-ray computed tomography confirms the enhancement of electrochemical surface area of the carbon electrodes due to N-G while electrochemical impedance spectra show the effect of its higher conductivity on improving RFB performance. Finally, potential strategies for the scaling-up of DES-based VRFBs using a simple economical model are also briefly discussed. From this study, it is deduced that more investigations on applying DESs as non-aqueous electrolytes to replace the commonly used acetonitrile may be a positive step forward because DESs are not only cheaper but also safer to handle, far less toxic, non-flammable, and less volatile than acetonitrile. Full article

This paper introduces a physical–chemical model that governs the lithium ion (Li-ion) battery performance. It starts from the model of battery life and moves forward with simplifications based on the single-particle model (SPM), until arriving at a more simplified and computationally fast model. On the other hand, the implementation of this model is developed through MATLAB. The goal is to characterize an Li-ion cell and obtain its charging and discharging curves with different current rates and different cycle depths, as well as its transitory response. In addition, the results provided are represented and compared, and different methods of estimating the state of the batteries are applied. They include the dynamics of the electrolyte and the effects of aging caused by a high number of charging and discharging cycles of the batteries. A complete comparison with the three-parameter method (TPM) is represented in order to demonstrate the superiority of the applied methodology. Full article

Lithium–oxygen (Li-O₂) batteries require scalable air electrode concepts and a sensible choice of operation parameters to achieve their promised energy densities. Furthermore, different test parameters are often investigated individually, but rarely brought together in order to optimize the discharge process and unlock the full discharge capability of an air electrode. In this work, we present a highly porous electrode based on graphite nanosheets (GNS) and discuss the impact of the discharge current density and the oxygen pressure as battery test parameters, as well as the electrolyte salt and volume, on the discharge behavior. In particular, changing the electrolyte salt from LiNO₃ to LiTFSI proved to be an important step towards better cell performance, because synergistic effects of the electrolyte and GNS greatly enhance the carbon-specific capacity. The optimized combination of the aforementioned parameters enabled a remarkably high discharge capacity of 56.3 mAh/cm² (5860 mAh/g_carbon) obtained at 150 µA/cm² (15.6 mA/g_carbon), resulting in the almost complete conversion of the lithium anode. These experimental results are an important step towards practical high-capacity air electrodes for Li-O₂ batteries. Full article

Temperature heavily affects the behavior of any energy storage chemistries. In particular, lithium-ion batteries (LIBs) play a significant role in almost all storage application fields, including Electric Vehicles (EVs). Therefore, a full comprehension of the influence of the temperature on the key cell components and their governing equations is mandatory for the effective integration of LIBs into the application. If the battery is exposed to extreme thermal environments or the desired temperature cannot be maintained, the rates of chemical reactions and/or the mobility of the active species may change drastically. The alteration of properties of LIBs with temperature may create at best a performance problem and at worst a safety problem. Despite the presence of many reports on LIBs in the literature, their industrial realization has still been difficult, as the technologies developed in different labs have not been standardized yet. Thus, the field requires a systematic analysis of the effect of temperature on the critical properties of LIBs. In this paper, we report a comprehensive review of the effect of temperature on the properties of LIBs such as performance, cycle life, and safety. In addition, we focus on the alterations in resistances, energy losses, physicochemical properties, and aging mechanism when the temperature of LIBs are not under control. Full article