Abstract
With the rapid development of electric vehicles, the safety accidents caused by the damage and failure of lithium-ion batteries under mechanical load are increasing gradually, which increases the significance of collision safety in lithium-ion batteries. The failure threshold of the cell in a free state is different from that of the cells in the module. Therefore, the safety characteristics of cells and modules under vertical dynamic impact conditions were studied in this paper. Lithium iron phosphate (LiFePO4) batteries and assembled 2-in-10 series modules with a 100% state of charge (SOC) were tested. Analyses included the voltage, temperature, and mechanical behavior of test samples under different impact loads, extrusion positions, and indenter shapes. The results showed that the damage behavior of a battery was closely related to the contact shape, contact area, and contact position. A smaller contact area led to greater deformation; moreover, the contact area being closer to the edge position meant greater deformation and weaker load-carrying capacity. The load-carrying capacity of the cell in a free state was weaker than that of the module, but the failure threshold of the cell in a free state was higher than that of the module. It can be concluded that the failure threshold of the cell cannot reflect the failure threshold of the module.