Fast charging of lithium-ion batteries presents significant thermal management challenges, particularly under demanding conditions involving high C-rates and extreme ambient temperatures. This study explores the thermal behavior of a cylindrical lithium-ion cell during fast-charging scenarios designed to achieve a full charge in 15 minutes or less, across a wide range of ambient temperatures. The analysis covers a broad spectrum of ambient temperatures, from subzero to excessively high, addressing real-world operational challenges faced by electric vehicles and energy storage systems.
A validated thermal model, calibrated with experimental data on the open circuit voltage (OCV) and internal resistance of the cell across varying conditions, is employed to accurately predict the temperature distribution of the cell across different states of charge (SOC). The model also includes scenarios involving high initial cell temperatures to assess their effect on thermal performance during fast charging.
To mitigate the thermal stresses generated by these extreme charging conditions, a novel Battery Thermal Management System (BTMS) is proposed and analyzed. This advanced cooling system is specifically engineered to manage the rapid heat generation associated with fast charging, ensuring safe and efficient operation across a wide range of harsh ambient temperatures.
Simulation results confirm the effectiveness of the BTMS in maintaining cell temperatures within safe operational limits, minimizing thermal gradients, and preventing overheating even in the most challenging conditions. The study underscores the critical relationship between charging strategies, ambient temperature variations, and cooling mechanisms, offering practical insights for the design of robust, next-generation thermal management solutions.
This research contributes to advancing fast-charging capabilities for high-capacity lithium-ion cells, offering a pathway to safer, more efficient, and thermally stable operation in electric vehicles and energy storage systems, even under extreme environmental and operational conditions.