Fast-charging performance and optimal thermal management of large-format full-tab cylindrical lithium-ion cells under varying environmental conditions

Various automobile manufacturers have announced utilization of large-format cylindrical lithium-ion cells with innovative tab design for future vehicle generations. In this study, a cylindrical lithium-ion cell with novel full-tab design, state-of-the-art Ni-rich cathode and SiOx-C anode made specifically for automotive high-performance applications is used to parameterize a modeling framework and investigate the performance of large-format cylindrical cells. Much attention is paid to accurately modeling and validating the internal heat path of the enhanced tab design that is crucial for effective thermal management and is one of the biggest advantages compared to former single-tab cells. The spatially-resolved physico-chemical model is extensively validated within the temperature range of −20 °C to 65 °C with experimental data from multiple different test setups. The validated model is used to investigate optimal fast-charging times and thermal management strategies based on local anode voltage and plating risk under varying environmental condition. The findings are summarized in a generalized cooling-and-heating-map that provides an outlook on the fast-charging performance of less than 12 minutes from 10% to 80% state of charge for large-format cylindrical cells.