Abstract
To assist in light weighting of electric vehicles by improving the volumetric and gravimetric energy density and the structural performance of the battery pack, a modelling methodology based on a macro finite element model of a pouch cell has been developed. This model treats the core cell structure as a homogeneous orthotropic honeycomb block with the pouch material being defined as an orthotropic fabric with compressive stress elimination. The model considers five compression and bending load cases simultaneously and allows a level of element discretisation that is computationally efficient and appropriate for inclusion in full vehicle and sub-system simulations. The methodology is scalable in that it can be applied to a range of chemistries, external geometries and internal cell constructions. When considering stacks of cells, the model is predictive for both lateral compression and three-point bend, but further work is required to improve the confined compression response.