Novel 18650 lithium-ion battery surrogate cell design with anisotropic thermophysical properties for studying failure events

Abstract Cylindrical 18650-type surrogate cells were designed and fabricated to mimic the thermophysical properties and behavior of active lithium-ion batteries. An internal jelly roll geometry consisting of alternating stainless steel and mica layers was created, and numerous techniques were used to estimate thermophysical properties. Surrogate cell density was measured to be 1593 ± 30 kg/m3, and heat capacity was found to be 727 ± 18 J/kg-K. Axial thermal conductivity was determined to be 5.1 ± 0.6 W/m-K, which was over an order of magnitude higher than radial thermal conductivity due to jelly roll anisotropy. Radial heating experiments were combined with numerical and analytical solutions to the time-dependent, radial heat conduction equation, and from the numerical method an additional estimate for heat capacity of 805 ± 23 J/kg-K was found. Using both heat capacities and analysis techniques, values for radial thermal conductivity were between 0.120 and 0.197 W/m-K. Under normal operating conditions, relatively low radial temperature distributions were observed; however, during extreme battery failure with a hexagonal cell package, instantaneous radial temperature distributions as high as 43–71 °C were seen. For a vertical cell package, even during adjacent cell failure, similar homogeneity in internal temperatures were observed, demonstrating thermal anisotropy.