Effect of packaging and cooling plates on mechanical response and failure characteristics of automotive Li-ion battery modules

When a battery pack is subjected to external mechanical load, i.e. as in the case of crash, the individual cells experience significant deformations leading to the internal short circuit and possibly fire. The current investigation looks into effects of the inactive components (i.e. cooling plates and module protective enclosure) on deformation and failure of individual pouch cells. Experiments on large spherical indentation of electric vehicle battery module with and without such components have been performed. The results show that the presence of cooling plates overall reduces the force under out-of-plane indentation by approximately a factor of 1.5. It was established however that the failure in cells occurs at the same displacement of the indenter, regardless of the presence of the inactive elements in battery module structure. This underlines the necessity for formulation of the failure criterion based on critical strain, rather than critical stress measure. The findings suggest possibility of utilizing such battery modules in impact energy absorption scenarios, due to reduction in force by the cooling components. X-Ray computed tomography (XCT) has been performed on the cells as a non-destructive analysis of internal failure and the differences of failure mode induced by introduction of structural components are discussed.