Electrochemical Thermal Stress Three-Dimensional Coupling Modeling and Stress Distribution Research of Lithium-Ion Batteries
Liu Suzhen1,2, Chen Yongbo1,2, Zhang Chuang1,2, Xu Zhicheng1,2, Jin Liang1,2
1. State Key Laboratory of Reliability and Intelligence of Electrical Equipment Hebei University of Technology Tianjin 300130 China; 2. Key Laboratory of Electromagnetic Field and Electrical Apparatus Reliability of Hebei Province Hebei University of Technology Tianjin 300130 China
Abstract：Lithium-ion battery charging and discharging is a complex process involving coupled electrochemical, mechanical, and thermal fields. During this process, diffusion-induced stress and thermal stress generated internally can lead to mechanical damage, such as electrode material fragmentation, detachment, and failure. Understanding the distribution and evolution of internal stress in lithium-ion batteries is crucial for studying the factors influencing battery stress, optimizing battery design, reducing internal stress, and extending battery lifespan. However, current experimental studies on stress have limitations, measurements based on optical principles are complex and expensive, and external stress sensors cannot directly obtain the full-field stress distribution inside the battery. Furthermore, research on stress models within lithium-ion batteries focuses on diffusion-induced stress at the cell level, often neglecting thermal stress from heat expansion. This paper establishes a three-dimensional electrochemical-thermal-mechanical coupling model for lithium-ion batteries combined with experiment and simulation. The stress distribution inside the battery is investigated. Firstly, a pseudo-two-dimensional electrochemical model is used for lithium-ion batteries, integrating the expansion and contraction effects caused by lithium-ion concentration variations and thermal expansion effects from temperature changes. The electrochemical-thermal-mechanical coupling model is established. Secondly, a charging and discharging test platform is constructed to measure the battery’s voltage, temperature, and surface pressure under different charging and discharging rates. The accuracy of the model is validated by comparing experimental and calculated results. Finally, this paper analyzes the battery’s electrochemical, thermal, and mechanical performance during constant-current charging. The distribution patterns of electrochemical, temperature, and stress fields are explored. Simulation and experimental results indicate that during constant-current charging of lithium-ion batteries, due to expansion, the surface pressure gradually increases and reaches its maximum at the end of charging as the state of charge (SOC) increases. As the charging rate increases, the rise in surface pressure accelerates, but SOC reduces at the end of constant-current charging because of polarization effects. The maximum surface pressure at the end of constant-current charging decreases with the increasing rate. The total stress inside the lithium-ion battery is the combination of diffusion-induced stress and thermal stress, with thermal stress being smaller in magnitude than diffusion-induced stress. Since heat generation increases, thermal stress is slightly greater than diffusion-induced stress and increases with the charging and discharging rate. Due to polarization effects and different mechanical parameters, there is non-uniform diffusion-induced stress within the battery. Larger diffusion-induced stress is generated in the positive and negative electrode active layers, with more pronounced non-uniform stress observed in the negative electrode active layer. It can be predicted that with increasing cycles, non-uniform stress and deformation will lead to uneven aging. This model provides theoretical guidance for designing internal structural parameters, selecting battery operating environments, and alleviating internal or non-uniform internal stress to extend battery lifespan.
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2025, Vol. 40 
