Structural Integrity and Thermal Management Assessment of Lithium-Ion Batteries under Crash Test for Different Cell Form Factors

Abstract

The safety of lithium-ion batteries (LIBs) in electric vehicles critically depends on their structural integrity and thermal stability under crash scenarios. This study presents a comprehensive assessment of cylindrical, prismatic, and pouch cell form factors through both experimental crash testing and finite element simulations using LS-DYNA and coupled thermal models. Structural responses, including stress distribution, deformation modes, and energy absorption, were analysed alongside thermal effects such as heat generation, dissipation, and risk of thermal runaway. Experimental observations were used to validate numerical results, ensuring accuracy in predicting coupled mechanical–thermal interactions. Comparative analysis revealed that cylindrical cells exhibit superior load-bearing capacity and delayed onset of thermal instability, prismatic cells are prone to localised stress concentrations, and pouch cells demonstrate higher vulnerability to deformation-induced heating. The novelty of this work lies in integrating structural crashworthiness with thermal management evaluation across different cell geometries, bridging a critical research gap in battery safety assessment. The findings provide actionable insights for optimised cell and pack design, development of crashworthiness standards, and formulation of advanced thermal management strategies, ultimately enhancing the safety and durability of next-generation EV battery systems.