Thermal Management in Lithium-Ion Batteries: Latest Advances and Prospects

A special issue of Batteries (ISSN 2313-0105). This special issue belongs to the section "Battery Performance, Ageing, Reliability and Safety".

Deadline for manuscript submissions: 15 May 2025 | Viewed by 20369

Special Issue Editors


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Guest Editor
Department of Mechanical Engineering and Materials Science, Washington University in St. Louis, St. Louis, MO 63130, USA
Interests: fuel cells; Li-O2 batteries; battery thermal management; heat and mass transfer in porous media

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Guest Editor
National Renewable Energy Laboratory, Golden, CO 80401, USA
Interests: Li-ion battery; multiphysics modeling; battery safety and thermal management; fluid dynamics and control

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Guest Editor
Skyline Mobility Inc., Torrance, CA 90501, USA
Interests: battery thermal management system; BMS algorithms; modeling and simulation (CFD/FEA); aerodynamics

Special Issue Information

Dear Colleagues,

The rapidly expanding battery market presents an urgent requirement for reliable, efficient, and affordable thermal management and protection solutions. These solutions are crucial to improve the cycle life and performance, as well as to mitigate the risk of thermal runaway and catastrophic failures in battery packs. Addressing these pressing needs is of the utmost importance for the power electronics, electric vehicle, and battery industries. By enhancing the safety of battery packs, we can facilitate the widespread adoption of batteries in energy-intensive applications such as electric vehicles and grid-scale energy storage systems. In addition, a higher battery cycle life improves the long-term cost–benefit of a battery electric vehicle or energy storage system. Advanced thermal management strategies can also improve performance, such as fast charging and aggressive discharges across a large temperature band, which further supports battery technology adaptation. Therefore, there is a critical imperative to develop robust, efficient, and cost-effective thermal management strategies that ensure the performance, integrity, and stability of battery systems.

In light of the rapid growth witnessed in the electric vehicle and rechargeable battery markets, this Special Issue, entitled “Thermal Management in Lithium-Ion Batteries: Latest Advances and Prospects”, presents an opportune platform to explore diverse thermal management technologies. It specifically focuses on their application in battery and electronics systems for transportation applications, including passenger cars, trucks, buses, locomotives, boats, aircraft, and beyond, encompassing both established industry practices and emerging solutions for future advancements. By examining conventional approaches alongside cutting-edge innovations, this timely collection of articles aims to address the evolving demands of the field and foster insights into effective thermal management strategies.

We encourage contributions from diverse global stakeholders to foster a comprehensive and inclusive dialogue. Valuable insights and expertise from academic institutions, industry organizations, and national laboratories are highly valued and encouraged. Both experimental studies and numerical simulations are welcomed. Topics of interest for publication include, but are not limited to:

  • Assessment of industry approaches and emerging advancements;
  • Single-phase cooling (passive, direct active, indirect active, and hybrid);
  • Multi-phase cooling (phase change materials, evaporative cooling, immersion/submerged cooling);
  • Innovative cooling materials and structures;
  • Advanced sensors, thermal control, and fault detection;
  • Battery materials and designs with improved thermal properties;
  • Strategies to mitigate thermal runaway and propagation;
  • Cutting-edge models to gain insights into thermal-related degradation mechanisms;
  • New mechanistic models to understand degradation caused by thermal issues;
  • Fusion of machine learning algorithms to enhance the precision and efficiency of detection and prediction;
  • Extreme conditions such as extremely fast charge and low temperatures.

Dr. Xianglin Li
Dr. Chuanbo Yang
Dr. Prahit Dubey
Guest Editors

Manuscript Submission Information

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Published Papers (4 papers)

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Research

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16 pages, 18315 KiB  
Article
Effects of Non-Uniform Temperature Distribution on the Degradation of Liquid-Cooled Parallel-Connected Lithium-Ion Cells
by Takuto Iriyama, Muriel Carter, Gabriel M. Cavalheiro, Pragati Poudel, George J. Nelson and Guangsheng Zhang
Batteries 2024, 10(8), 274; https://doi.org/10.3390/batteries10080274 - 30 Jul 2024
Viewed by 1137
Abstract
Our previous work on an air-cooled stack of five pouch-format lithium-ion (Li-ion) cells showed that non-uniform temperature can cause accelerated degradation, especially of the middle cell. In this work, a stack of five similar cells was cycled at a higher C-rate and water-cooled [...] Read more.
Our previous work on an air-cooled stack of five pouch-format lithium-ion (Li-ion) cells showed that non-uniform temperature can cause accelerated degradation, especially of the middle cell. In this work, a stack of five similar cells was cycled at a higher C-rate and water-cooled to create a larger temperature gradient for comparison with the air-cooled stack. It was hypothesized that the larger temperature gradient in the water-cooled stack would exacerbate the degradation of the middle cell. However, the results showed that the middle cell degraded slightly slower than the side cells in the water-cooled stack. This trend is opposite to that in the air-cooled stack. This difference could be attributed to the combined effects of a smaller temperature rise and larger temperature gradient in the water-cooled stack than in the air-cooled stack. Post-mortem analysis of cycled cells and a fresh cell showed that the degradation mainly came from the anode. Increased lithium plating and decreased porosity in the side cells are possible mechanisms for the faster degradation compared with the middle cell. It was also found that all the cells in the water-cooled stack experienced a phenomenon of capacity drop and recovery after a low C-rate reference performance test and extended rest. This phenomenon can be attributed to lithium diffusion between the anode active area and the anode overhang area. Full article
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12 pages, 2116 KiB  
Article
Li-Ion Battery Thermal Characterization for Thermal Management Design
by Aron Saxon, Chuanbo Yang, Shriram Santhanagopalan, Matthew Keyser and Andrew Colclasure
Batteries 2024, 10(4), 136; https://doi.org/10.3390/batteries10040136 - 18 Apr 2024
Cited by 3 | Viewed by 2584
Abstract
Battery design efforts often prioritize enhancing the energy density of the active materials and their utilization. However, optimizing thermal management systems at both the cell and pack levels is also key to achieving mission-relevant battery design. Battery thermal management systems, responsible for managing [...] Read more.
Battery design efforts often prioritize enhancing the energy density of the active materials and their utilization. However, optimizing thermal management systems at both the cell and pack levels is also key to achieving mission-relevant battery design. Battery thermal management systems, responsible for managing the thermal profile of battery cells, are crucial for balancing the trade-offs between battery performance and lifetime. Designing such systems requires accounting for the multitude of heat sources within battery cells and packs. This paper provides a summary of heat generation characterizations observed in several commercial Li-ion battery cells using isothermal battery calorimetry. The primary focus is on assessing the impact of temperatures, C-rates, and formation cycles. Moreover, a module-level characterization demonstrated the significant additional heat generated by module interconnects. Characterizing heat signatures at each level helps inform manufacturing at the design, production, and characterization phases that might otherwise go unaccounted for at the full pack level. Further testing of a 5 kWh battery pack revealed that a considerable temperature non-uniformity may arise due to inefficient cooling arrangements. To mitigate this type of challenge, a combined thermal characterization and multi-domain modeling approach is proposed, offering a solution without the need for constructing a costly module prototype. Full article
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Review

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20 pages, 950 KiB  
Review
Recent Advances in Thermal Management Strategies for Lithium-Ion Batteries: A Comprehensive Review
by Yadyra Ortiz, Paul Arévalo, Diego Peña and Francisco Jurado
Batteries 2024, 10(3), 83; https://doi.org/10.3390/batteries10030083 - 1 Mar 2024
Cited by 1 | Viewed by 7556
Abstract
Effective thermal management is essential for ensuring the safety, performance, and longevity of lithium-ion batteries across diverse applications, from electric vehicles to energy storage systems. This paper presents a thorough review of thermal management strategies, emphasizing recent advancements and future prospects. The analysis [...] Read more.
Effective thermal management is essential for ensuring the safety, performance, and longevity of lithium-ion batteries across diverse applications, from electric vehicles to energy storage systems. This paper presents a thorough review of thermal management strategies, emphasizing recent advancements and future prospects. The analysis begins with an evaluation of industry-standard practices and their limitations, followed by a detailed examination of single-phase and multi-phase cooling approaches. Successful implementations and challenges are discussed through relevant examples. The exploration extends to innovative materials and structures that augment thermal efficiency, along with advanced sensors and thermal control systems for real-time monitoring. The paper addresses strategies for mitigating the risks of overheating and propagation. Furthermore, it highlights the significance of advanced models and numerical simulations in comprehending long-term thermal degradation. The integration of machine learning algorithms is explored to enhance precision in detecting and predicting thermal issues. The review concludes with an analysis of challenges and solutions in thermal management under extreme conditions, including ultra-fast charging and low temperatures. In summary, this comprehensive review offers insights into current and future strategies for lithium-ion battery thermal management, with a dedicated focus on improving the safety, performance, and durability of these vital energy sources. Full article
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45 pages, 13074 KiB  
Review
Review of Thermal Management Strategies for Cylindrical Lithium-Ion Battery Packs
by Mohammad Ahmadian-Elmi and Peng Zhao
Batteries 2024, 10(2), 50; https://doi.org/10.3390/batteries10020050 - 28 Jan 2024
Cited by 5 | Viewed by 7780
Abstract
This paper presents a comprehensive review of the thermal management strategies employed in cylindrical lithium-ion battery packs, with a focus on enhancing performance, safety, and lifespan. Effective thermal management is critical to retain battery cycle life and mitigate safety issues such as thermal [...] Read more.
This paper presents a comprehensive review of the thermal management strategies employed in cylindrical lithium-ion battery packs, with a focus on enhancing performance, safety, and lifespan. Effective thermal management is critical to retain battery cycle life and mitigate safety issues such as thermal runaway. This review covers four major thermal management techniques: air cooling, liquid cooling, phase-change materials (PCM), and hybrid methods. Air-cooling strategies are analyzed for their simplicity and cost-effectiveness, while liquid-cooling systems are explored for their superior heat dissipation capabilities. Phase-change materials, with their latent heat absorption and release properties, are evaluated as potential passive cooling solutions. Additionally, hybrid methods, such as combining two or more strategies, are discussed for their synergistic effects in achieving optimal thermal management. Each strategy is assessed in terms of its thermal performance, energy efficiency, cost implications, and applicability to cylindrical lithium-ion battery packs. The paper provides valuable insights into the strengths and limitations of each technique, offering a comprehensive guide for researchers, engineers, and policymakers in the field of energy storage. The findings contribute to the ongoing efforts to develop efficient and sustainable thermal management solutions for cylindrical lithium-ion battery packs in various applications. Full article
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Planned Papers

The below list represents only planned manuscripts. Some of these manuscripts have not been received by the Editorial Office yet. Papers submitted to MDPI journals are subject to peer-review.

Title: Recent Progress of Deep Learning Methods for Health Monitoring of Lithium-ion Batteries
Authors: Seyed Saeed Madani 1; Parisa Vahdatkhah 2; S.K. Sadrnezhaad 2; Carlos Ziebert 1
Affiliation: 1. Institute of Applied Materials-Applied Materials Physics, Karlsruhe Institute of Technology, 76344 Eggenstein-Leopoldshafen, Germany; 2. Department of Materials Science and Engineering, Sharif University of Technology, Tehran 11365-9466, Iran
Abstract: In recent years, the field of transportation electrification has experienced significant advancements, predominantly driven by the adoption of lithium-ion batteries (LIBs) as the primary energy storage solution. Ensuring the safe and efficient operation of these LIBs is imperative, and Battery Management Systems (BMS) play a pivotal role in this regard. Within the spectrum of BMS functions, state and temperature monitoring stand out as critical aspects for intelligent LIB management. Accurate prediction of the state of health (SOH) of LIBs not only extends battery lifespan but also provides invaluable insights for optimizing battery usage. Furthermore, precise estimation of the Remaining Useful Life (RUL) of Li-ion batteries is essential for achieving efficient battery management and state estimation. As the demand for electric vehicles continues to rise, the necessity for advanced RUL prediction techniques becomes increasingly evident. This review underscores the significance of Machine Learning (ML) techniques in precisely predicting LIB states while simultaneously reducing computational complexity. It sheds light on the present state of research in the field and outlines promising future avenues for leveraging ML in the context of lithium-ion batteries. This comprehensive review also identifies existing challenges and proposes a structured framework to address these obstacles, focusing on the development of machine-learning applications tailored specifically for rechargeable LIBs. By harnessing the power of Artificial Intelligence (AI) technologies, researchers aspire to expedite advancements in battery performance and overcome the present limitations associated with lithium-ion batteries. The symmetrical approach of ML in this domain brings harmony to battery management and contributes to the sustainable progress of transportation electrification.

Title: Hybrid Heat Pipe-PCM-Assisted Thermal Management for Lithium-ion Batteries
Authors: Nourouddin Sharifi; Christian Millard; Hamidreza Shabgard
Affiliation: 1. Department of Engineering Technology, Tarleton State University, 1333 W. Washington Stephenville, TX 76402, USA; 2. Department of Mechanical, Environmental, and Civil Engineering, Tarleton State University, 1333 W. Washington Stephenville, TX 76402, USA; 3. School of Aerospace and Mechanical Engineering, University of Oklahoma, 865 Asp Ave., Norman, OK 73019, USA
Abstract: A hybrid cooling method for 18650 lithium-ion batteries has been studied experimentally and numerically for electric vehicle applications. The experimental setup consists of a heater section, a phase change material (PCM) reservoir, and a cooling section. The heater section mimics the heat generated by the batteries and includes two cylindrical aluminum housings with the same dimension as an 18650 battery, two cartridge heaters, and an aluminum heat sink. The PCM reservoir is made of PLA 3D-printed parts. An air flow channel is designed for the cooling section. Three copper-water heat pipes (HPs) are used to transfer the heat from the heaters to the air flow channel through the aluminum housings, the heat sink, and the PCM. Aluminum fin jackets are used on the HPs to improve the heat transfer rates. Temperatures at various locations within the setups are measured and compared across different heater powers and air velocities. It is concluded that the current experimental design is thermally efficient to bring the temperature of the batteries within an allowable operating temperature range for the conditions of the studies. Additionally, a transient three-dimensional numerical model is created in ANSYS-FLUENT, which is utilized to facilitate optimization study and offer insights into the physics of the problem. The phase change in the conjugate numerical model is accounted for by the enthalpy-porosity technique. The computational outcomes and the experimental data were reasonably in agreement.

Title: Smoke characteristics of 18650 Lithium-ion batteries during thermal abuse in non-confined environment
Authors: Pius Victor Chombo; Gerutu Bosinge Gerutu; Ramadhani Omary Kivugo; Kenedy Aliila Greyson
Affiliation: 1. Department of Electrical Engineering, Dar es Salaam Institute of Technology, Bibi Titi-Morogoro Road, Dar es Salaam 11104, Tanzania; 2. Department of Mechanical Engineering, Dar es Salaam Institute of Technology, Bibi Titi-Morogoro Road, Dar es Salaam 11104, Tanzania; 3. Department of Electronics and Telecommunication Engineering, Dar es Salaam Institute of Technology, Bibi Titi-Morogoro Road, Dar es Salaam 11104, Tanzania
Abstract: Due to the thermal sensitive and serious explosion behaviors of Lithium-ion batteries (LIBs), understanding the potential hazards during LIBs failure becomes useful to assess the safety of LIBs during storage, transport, and use. Smoke is an unavoidable effluent during LIB failure, and its constituents may pose serious hazards. Yet, there is little knowledge regarding the smoke characteristics of the failed LIB. This study broadly analyzes the smoke characteristics of 18650 LIBs with state of charge (SOC) from 25 to 100% triggered to TR by uniform heating in a non-confined environment. The smoke characteristics are analyzed in terms of filter smoke number (FSN) and soot concentration (Sconc) quantified during break out of safety vent (SV) and explosion triggered by thermal runaway (TR). Moreover, heat transfer (qrad and qconv) to the LIB is evaluated. Comparatively, qconv dominated the heat transferred, took up to 97.56% of the total heat received on the LIB under test. FSN was found to be less than one in all SOC and cathodic materials during the SV crack and reached 3.80 at 75% SOC in LCO LIB at TR stage. However, Sconc during SV and TR reached a maximum of 12.90 and 75.05 mg/kg at 100 and 50% SOC in LCO and NCA LIBs. Findings showed that the heat during onset of TR (qTR) ranged between 1.54 to 1.88; 1.86 to 1.89; and 1.51 to 2.08 for NCA, LCO and LMO, respectively. The growth rate for FSN ranged between 0.003782 and 0.016602 per unit of qTR, while growth rate for Sconc is between 0.059488 and 0.537933 per unit of qTR. In terms of energy, the normalized FSN and Sconc for NCA, LCO and LMO ranged between 0.82 ± 0.018 FSN/Wh and 22.40 ± 0.012 mg/kg.Wh; 1.17 ± 0.014 FSN/Wh and 27.49 ± 0.028 mg/kg.Wh; 0.51 ± 0.004 FSN/Wh and 10.27 ± 0.038 mg/kg.Wh, respectively. This work delivers new insights into the effects of SOC, cathode materials, and external heat energy on the FSN and Sconc, which helps to dictate the safety of both first and second responders in case of large-scale applications.

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