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Mechanical Intrusion of Aged Lithium-Ion Batteries: Boundary-Condition Continuity, Trigger Definitions, and the Limits of Cross-Study Comparability
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DOI：10.3390/batteries12080282.png)
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Abstract
En 中文
Indentation and crush tests are widely used as crash-relevant surrogates for mechanical intrusion in Lithium-Ion Batterys (LIBs), yet their interpretation still relies on macroscopic, binary pass/fail criteria established at the Beginning of Life (BoL). This neglects how calendar and cyclic degradation alter a cell’s mechanical, thermal, and structural state before abuse, leaving the literature on aged cells apparently contradictory. This review establishes an aging-aware interpretive framework that separates three levels commonly conflated: the boundary conditions governing deformation, the study-specific criteria and evidence strength behind a declared electrical event, and the post-trigger hazard progression captured within the available monitoring window. A descriptive synthesis of 22 normalized fresh-to-aged comparisons from 13 primary studies shows no universal aging-driven shift of the reported comparison event toward earlier or later force–displacement states, with force and displacement changing in the same direction in only about half of the cases. An apparent format-associated displacement pattern is substantially attenuated when the pouch-cell displacement ratios are normalized by the respective initial cell thicknesses: the pouch-cell median displacement ratio decreases from 1.07 to approximately 1.00, and the remaining variation differs across aging routes and states of charge, although their individual contributions cannot be separated in the available dataset. Many apparent contradictions likewise stem from non-equivalent mechanical boundary conditions and trigger definitions, and continuity of confinement—especially for pouch cells aged under stack pressure and tested in a relaxed state—is identified as a frequently overlooked interpretive variable, although no controlled aged-cell study has yet isolated its contribution. An earlier-reported trigger does not necessarily imply a more severe outcome. We distill these requirements into a tier-resolved reporting checklist, providing a more rigorous and reusable basis for abuse-test interpretation, model development, and safety qualification of batteries intended for long service life and second-life deployment.
Keywords:
lithium-ion batteries
mechanical intrusion
indentation
crush
aging
confinement continuity
cell-format-associated patterns
regulatory testing
diagnostics
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