Electro-Thermal Degradation Modeling for Fast-Charging Large-Format Prismatic Cells
Electro-thermal degradation modeling reveals that internal thermal gradients accelerate localized lithium plating and active inventory loss during fast charging.
Terminal Tab Heating
Meaning
Temperature increase occurs at the thin metal strips that connect the internal electrode stack to the external battery terminals. Terminal tab heating is a result of the electrical resistance in the junction where current is most concentrated. During high power discharge or fast charging, these small components can reach temperatures much higher than the rest of the cell.
Resistive Loss
Joule heating at the tabs accounts for a large portion of the total thermal load in a battery pack. If terminal tab heating is not controlled, the localized heat can degrade the nearby separator or melt the plastic seals. Engineers reduce this effect by using thicker materials or multiple tabs to distribute the current more evenly.
Thermal Regulation
Sensors placed near the terminals monitor these hotspots to prevent damage to the electronics. Persistent terminal tab heating limits the continuous current rating of the battery system. Effective cooling strategies often target these specific points to maintain a stable operating temperature during heavy use.
Safety Margin
Excessive heat at the connection points can lead to the failure of the cell casing or internal venting. Managing the intensity of terminal tab heating is a critical part of the design process for high performance packs. It ensures that the electrical path remains stable even under extreme load conditions.