Testing and Modeling of Vehicle Li-Ion Battery Module with Prismatic Cells under Abuse Conditions

The damage behavior of Li-ion vehicle battery modules with prismatic cells has been investigated through mechanical experiments and numerical simulations. The modules were subjected to quasi-static indentation using a V-shaped stainless-steel wedge along three orthogonal directions. One higher speed test was also performed. Force and voltage were measured as a function of displacement to monitor damage during loading. A detailed finite element (FE) model was developed to simulate force-displacement with very good comparison to experimental results. Based on the FE model, energy absorption contributions of four major component groups were analyzed along with detailed effects of enclosure weld defects. Analysis indicates the steel parts absorbed significant amounts of energy irrespective of indentation direction. The welds connecting the side plates were the weak link in the protective structure. Increasing the thickness of the steel plates could help absorb more energy.