Latest battery design articles

All of the latest battery design articles are listed below. This list of battery design articles refreshes and new articles will appear here on top. Click here to return to main page. if you are interested to help us write articles, do reach out to us. Email: or on LinkedIn.

  • Exploring Different Battery Tray Designs
    Exploring different battery tray designs in the automotive industry and three main design concepts have emerged in the design of metallic battery trays: Building on Posts from Matthias Biegerl [1] and Luca Greco [2]. Deep-Drawn Sheet Metal Pans This process involves forming the … Read more
  • Zeekr 140kWh CATL Qilin
    The Zeekr 140kWh CATL Qilin battery pack is interesting as it is an NMC chemistry in a cell to pack design. This pack is used in the 001 and 009. Specifications This post has been built based on the support and sponsorship from: Thermo … Read more
  • Enhancing Lithium-Ion Battery Management with Advanced Kalman Filter Tuning
    Enhancing Lithium-Ion Battery Management with Advanced Kalman Filter Tuning summarises the work conducted by Jasper Knox, Mark Blyth and Alastair Hales (all University of Bristol). Lithium-ion batteries are integral to modern electric vehicle development, requiring advanced battery management systems (BMS) for effective battery … Read more
  • Impact of SOC Estimation Error
    An initial high level look at the impact SOC estimation errors. State of Charge (SOC) State of Charge, abbreviated as SOC and defined as the amount of charge in the cell as a percentage compared to the nominal capacity of the cell in … Read more
  • Mapping Pouch Cell Pressure Distribution in Operando
    CompreCell Pouch x TekScan Sensor Author: rhd instruments GmbH & Co. KG Introduction The pressure applied to pouch cell batteries is key to their performance and cycle life [1, 2, 3, 4]. One of two modes of pressure application is typically used: Constant … Read more
  • Series and Parallel Calculations
    When designing a battery pack it is useful to make a few series and parallel calculations. Hence one of the worksheets in our Battery Calculations Workbook is exactly that. Cells that are in parallel have the positive terminals all connected together and the … Read more
  • Geely Aegis Short Blade Battery
    Look at the data and what we can infer about the Geely Aegis Short Blade battery cell. A blade cell that has an energy density of 192Wh/kg. We know that this cell is destined for the Geely Galaxy E5 and has two pack … Read more
  • 2024 Audi Q6 SUV e-tron quattro
    The 2024 Audi Q6 SUV e-tron quattro has a 100kWh battery pack that uses large CATL prismatic cells. A rectangular flat pack design. The first of Audi’s production vehicles based on the Premium Platform Electric (PPE) architecture. The Audi video shows that the … Read more
  • 2022 GAC Aion Y Plus
    Here we take a look at the 2022 GAC Aion Y Plus that uses a CALB NMC battery pack. The battery pack nameplate shows the manufacturer, nominal voltage, capacity and the weight of the pack. This post has been built based on the … Read more
  • Cycle Life and Energy Density
    Is there a relationship between Cycle Life and Energy Density? This is a mix of chemistry, age, size and manufacturers. Hence a lot of other information mixed into this, but there is a trend. Adding trendlines might be generous, but what we can … Read more
  • 2022 Kia EV6
    The 2022 Kia EV6 is an interesting vehicle, perhaps mostly because of the specifications around the battery pack. Specifications that have been achieved with some small steps in design. This platform is shared with the Hyundai Ioniq 5. The 2021 Hyundai Ioniq 5 … Read more
  • Benchmarking Modules
    What do you need to know when benchmarking modules? This is all part of our thought process so that we can start to pull together the data you need. Hence, a high level list: This post has been built based on the support … Read more
  • Blade or Prismatic
    What makes a Blade or Prismatic cell what it is? Blade cells are long, thin and have a terminal at each end. But so do some prismatic cells. Is it the ratio of the side dimensions? The following graph shows data from the … Read more
  • CATL BTF0 161Ah LFP
    CATL BTF0 161Ah LFP is the cell used in the 55kWh Tesla Model 3 SR pack. Sandro Stock et al [1] have published a cell teardown and analysis. This gives an insight to the cell characteristics and design. The cell is made by … Read more
  • Prismatic Cell Electrode Estimation
    Using some simple mathematics and dimensions we can do some prismatic cell electrode estimation. The real challenge was: by giving following inputs (length, width & thickness of cathode, anode & separator, fixed mandrel length and dimensions of the prismatic cell case), can we … Read more
  • Pack Level Chemistry Comparison
    In this pack level chemistry comparison we have taken some generic chemistry values for NMC, LFP. LTO and NaB. Thus allowing us to do a very high comparison. The tool for this comparison is available in the Battery Calculations Workbook. Cell Data For … Read more
  • Weld Mechanical and Electrical Properties
    Is there a relationship netween weld mechanical and electrical properties? The basic conclusion is that low electrical resistances were found to correlate with high mechanical strengths of the welds. Correlation between electrical resistance and tensile strength for welds produced with (blue markers) and … Read more
  • BYD Shark PHEV
    Not many details around the BYD Shark PHEV, but worth sharing what we know. The image shows a rectangular battery pack, typical of the BYD Blade design. This uniform shape keeps the cost low, but will challenge the packaging of the driveline and … Read more
  • Mixed Chemistry Battery Pack
    The mixed chemistry battery pack consists of two types of battery cell with different chemistry in one battery pack. The aim being to offer the best of both chemistries: A look at the power density versus energy density graph. This shows that high … Read more
  • Benchmarking Battery Pack Volume
    Benchmarking battery pack volume is difficult as not many manufacturers give you a volume or even basic dimensions. This means we have to hunt for the data. Metrics In some cases manufacturers make a claim for the pack volumetric energy density. If you … Read more
  • BYD e-Platform 3.0
    The 2021 BYD e-Platform 3.0 brought quite a few changes to the battery pack design. Now with more data available it is worth a more detailed look. BYD make a number of claims around the battery in this design: The platform is likely … Read more
  • Performance Imbalances in Parallel-Connected Cells
    Efficiently addressing performance imbalances in parallel-connected cells is crucial in the rapidly developing area of lithium-ion battery technology. This is especially important as the need for more durable and efficient batteries rises in industries such as electric vehicles (EVs) and renewable energy storage … Read more
  • Electrolyte Fill Requirements
    What are the electrolyte fill requirements for a cell versus chemistry, capacity, format, lifetime and other parameters? The electrolyte is the medium that allows ionic transport between the electrodes during charging and discharging of a cell. Electrolytes in lithium ion batteries may either … Read more
  • Cell-to-Cell Variation and Deterministic Pack Effects
    How Random Cell-to-Cell Variation and Deterministic Pack Effects Determine Pack Capacities was a poster presented by Brill Power at the Oxford Battery Modelling Symposium 2024. This looked at how thermal gradient impacts battery cell degradation and consequently battery pack capacity. Written by: Jorn … Read more
  • Battery Cell Ragone Plot
    Battery cell ragone plot is power density vs energy density. A plot often used to compare chemistry. This plot needs to consider peak versus continuous power. The following plot is from the Cell Database. In this plot we can just about see a … Read more
  • Genuine P45B Tests
    Initial tests of the Molicel P45B 21700 cells. By Stéphane Melançon, Melstronic Conditions: Measured with calibrated precision class 0.01 instruments for rated capacity measurement STANDARD at C/5 …. and more. All measurement including recharge were made using 4 wire (Kelvin) connections for top accuracy. … Read more
  • What can we learn from Battery Benchmarking?
    What can we learn from Battery Benchmarking? was presented at the Battery Tech Show 2024 and has been abrieviated and turned into a post. We don’t have the resources to take batteries apart, but there are lots out there who do and they … Read more
  • Lithium Rich Manganese
    Lithium Rich Manganese (LRM) has a high specific capacity because of both cationic and anionic redox activity and are expected to be developed and applied as cathode materials for a new generation of high-energy density lithium-ion batteries [1]. Quan Li et al [2] show … Read more
  • 2024 AVATR 12
    The battery pack in the 2024 AVATR 12 is the CATL Qilin, a Cell to Pack design and in this case using NMC chemistry. The battery pack has a total energy of 94.5kWh and is described “Adaptive to DC fast charging piles with … Read more
  • Battery Pack Assembly Bill of Process
    A generic battery pack assembly bill of process that lays out the high level steps and challenges. In this process we are going from incoming battery cells and all sub-systems to tested complete battery pack. 1. Inbound Cells In high volume manufacturing the … Read more