Cylindrical 18650 and 21700 lithium-ion batteries are produced with small gaps between the jelly roll and the case. The size of these gaps and the mechanical attachment of the jelly roll to the case can have a significant impact on the thermal and mechanical properties of cells. To investigate the influence of the state of charge (SOC) and state of health (SOH) on the size of the gap, computed tomography (CT) and gray-value analysis was conducted with various cell types at 0% and 100% SOC and after cycling. The results show a significant influence of the SOC on the gap for new cells and a substantial reduction in the gap during the first cycles.
Electrochemical-mechanical interactions, in particular pressure-induced ones, have been identified to be a cause for lithium-plating in lithium-ion cells. Mechanically-induced porosity inhomogeneities in the separator layers due to electrode expansion during charging especially lead to cell internal balancing currents and can cause localized plating. To identify cell-format and cell-material dependent mechanical weak spots, a layer-resolved mechanical simulation of different cell types and cell-material combinations is presented in this work. The simulation results show distinctive layer strain patterns for different cell-types that coincide with localized lithium-plating found in post-mortem cells. Additionally, the effects of cell bracing in battery modules is investigated and a method to mitigate the increased layer strain due to bracing counterforces is proposed that also increases cell energy density for hardcase-type automotive cells.
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