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BLADE BATTERY TECHNOLOGY IN ELECTRIC VEHICLES: THERMAL
CHALLENGES, DEGRADATION MECHANISMS, AND MANAGEMENT
STRATEGIES
Almataev Tojiboy Orzikulovich
1
Zokirjonov Azizbek Zokirjon ugli
2
1
Professor of Andijan State Technical Institute
Address: Boburshoh Avenue 56, 170119, Andijan city, Republic of Uzbekistan
2
Ph.D. Scholar of Andijan State Technical Institute
Address: Boburshoh Avenue 56, 170119, Andijan city, Republic of Uzbekistan
E-mail: azokirjonov@andmiedu.uz
https://doi.org/10.5281/zenodo.15694602
Abstract
: Lithium-ion batteries have become a crucial factor in the widespread adoption
of electric vehicles, thanks to their high energy density and seamless integration with
powertrain systems. However, their performance is highly dependent on operating
temperature, necessitating an efficient thermal management system to ensure optimal
efficiency, safety, cost-effectiveness, and longevity, particularly in high-capacity Li-ion
batteries. This review provides a comprehensive analysis of heat generation mechanisms and
thermal modeling in lithium-ion batteries, along with various thermal management systems.
It examines the impact of extreme conditions on battery performance, including thermal
runaway and aging. Ultimately, it aims to establish a comprehensive framework for future
research and development in battery thermal management systems.
Keywords
: Electric vehicles, degradation, thermal condition, blade battery.
I. Introduction
As battery prices fall and battery technology itself improves, the world is taking note and
preparing for the electric vehicle revolution. Nearly all the major car manufacturers have
thriving electric vehicle practices. The state of California in the US, along with the US federal
government, is in fact offering substantial financial incentives to consumers purchasing
electric vehicles [1]. So, on a year-on-year basis, the share of electric vehicle sales, as a
percentage of overall vehicles sales, has been on the rise and this is a positive sign. As battery
manufacturing capacity ramps-up around the world, as the who’s who in car manufacturing
begin to take a notice, as governments catalyze the adoption of electric vehicles and as
consumers become aware of the environmental benefits, this share will continue to rise only
further from here on out [2]. There were over 10 million EVs sold worldwide in 2022, and the
market is expected to grow to 228 million by 2030 as a result of tight regulations in many
countries [3]. Developing electrochemical batteries for transportation applications have
begun in the 1990s with lead acid batteries and nickel metal hydride batteries (NiMH), while
these efforts led to the exploitation of the Nickel Sodium Chloride as a new electrical energy
storage option. As a result of their high energy and power density, EV manufacturers started
using Li-ion batteries for energy storage in 2010 [4]. In recent years, a variety of Li-ion
chemistry has been offered under the way of material development for expected application.
Lithium cobalt oxide (LCO) is a good-performing battery with a high energy density, but it is
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often used in small-scale applications due to its low thermal stability and still high price tag.
The NiCd and NiMH batteries are the upcoming deployed LIBs due to their high-power
density and affordable cost. Currently, batteries with a power density greater than 350 Wh/kg
use lithium manganese oxide (LMO), lithium nickel manganese cobalt oxide (NMC), lithium
nickel cobalt aluminum oxide (NCA), and lithium iron phosphate (LFP) as electrode materials.
There is a downside with LIB due to their sensitivity to the operating temperature, hindering
its way for faster market uptake. The accumulation of generated heat during the charging and
discharging process due to electrochemical process, especially in high-capacity batteries that
are more appealing for EV manufacturers may cause thermal runaway and degradation of
battery performance and even pose a threat to the safety of passengers [5]. According to the
usage of protocols 15–35
o
C is optimal for the operation of LIB. NiCd and NiMH batteries are
recommended for operation at temperatures between 20 and 32
o
C and − 20 to 45
o
C,
respectively [6]. Temperature deviation inside battery pack which directly affects the battery
electrical behavior is suggested to be maintained lower than 5
o
C to prevent uneven electrical
characteristic [7]. Operating the battery at low temperatures can also possess adverse effects,
such as capacity loss and degradation of active materials, due to decreased electrochemical
reaction rates [8]. To support the widespread adoption of electric vehicles in various
environmental conditions and to meet the demand for lifetime, longer mileage and proper
performance, an effective and economical battery thermal management system is necessary
to ensure suitable battery pack conditions. The battery thermal management system cools
down the Li-ion battery pack when the temperature rises over the allowed range and warms
up the battery pack when the environmental temperature is too low. Additionally, battery
thermal management system ensures a uniform distribution of temperatures among battery
packs to prevent uneven voltage of battery cells. Over the past few decades, various studies
have focused on the battery thermal management systems, which plays a critical role in
electric vehicle powertrains.
II. Blade Battery technologies in electric vehicle
Due to the lack of fuel and the severity of pollution, various manufacturers have
launched their own pure electric models, and the use of batteries is particularly critical. Many
new power manufacturers have no ability to produce batteries and can only use second-party
batteries. At present, lead-acid batteries, nickel-metal hydride batteries and lithium-ion
batteries are widely used [9]. But the problem of a spontaneous combustion caused by battery
temperature control and battery energy consumption remains to be solved. It is the massive
burning of fossil fuels that leads to energy shortage and air pollution that makes electric
vehicles slowly come to the stage. The emergence of electric vehicles is to solve these
problems, but the problem of batteries was not taken into account in the early stage. Although
the emergence of blade batteries cannot completely solve these problems, it can greatly
improve the original problems. This reviewed article specifically focused on the battery and
thermal conditions of domestic new energy manufacturers, the principles of new energy
manufacturers and BYD blade batteries, and the degradation behavior of blade batteries in
electric vehicles under severe thermal condition.
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Picture 1: The Blade battery structure of BYD
The Blade Battery, a type of lithium iron phosphate (LFP) battery, differs from
conventional LFP batteries primarily in its elongated, thin design. The driving range of an
electric vehicle is directly determined by the capacity of its power battery. The endurance
mileage of electric vehicles is actually the endurance capacity of power batteries for electric
vehicles. Simple analysis from top to bottom, the first level: if you want to improve the
endurance of the same car with the same weight, you need to increase the battery capacity.
level 2: improve battery capacity from two perspectives: one is to stack battery modules, the
other is to improve energy density. The former brings an increase in weight and a discount in
endurance, so improving energy density is the key. The third level: the key to improving
energy density lies in the selection and proportion of cell materials, the optimization of the
layout of battery internal space and the whole package space, and the "slimming" of the
weight of the whole module or pack. The blade battery is to make the cell into a blade shape.
The cell adopts laminated structure + ceramic coating technology Through structural
innovation, the “module” can be skipped in the group, that is, more batteries can be placed in
the unit space. The blade battery is a sublimation of lithium iron phosphate. From the second
law of improving energy density, the layout of the internal space and the whole package space
of the battery is optimized [10].
III. Degradation behavior of blade batteries in electric vehicles under severe
thermal condition.
Thermal management: The Blade Battery incorporates an integrated thermal
management system to dissipate heat effectively. By placing the battery cells in direct contact
with a thermally conductive material, the Blade Battery can maintain a stable operating
temperature, preventing overheating and reducing the risk of thermal issues [11]. In
traditional lithium-ion batteries, heat dissipation can be a challenge, leading to thermal
buildup and potential performance degradation [12]. Battery degradation in electric vehicles
is influenced by various factors, including user behavior and environmental conditions. The
daily driving distance of an electric vehicles affects the depth of discharge, which plays a key
role in battery wear. Driving speed and acceleration determine the discharge current,
impacting battery performance over time. Among environmental factors, temperature has the
most significant effect on battery aging, influencing both efficiency and long-term durability.
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Picture 2: The influence in battery degradation from common factors in driving
test.
The standby state takes up a considerable amount of time in electric vehicles’ real-life
operation, and the contribution to total aging is significant. The pace of the degradation
process during standby, known as calendar aging, varies depending on the SOC and
temperature. It is evident that the battery capacity fade is more notable at high temperatures
than at a moderate temperature. In addition, high state of charges will also accelerate capacity
fade due to the high voltage. As expected, the highest capacity degradation occurs in the
toughest conditions, with a high storage state of charge (80%), and the highest temperatures
(45
o
C) among these cases. Exposure to high temperatures, such as 45°C (113°F), can more
than double the rate of capacity loss compared to standard conditions (25°C or 77°F). For
instance, after 200 charge cycles, a battery at 45°C may lose approximately 6.7% of its
capacity, whereas at 25°C, the loss is around 3.3% This accelerated degradation is due to the
growth of the solid-electrolyte interphase (SEI) layer and lithium plating, which reduce the
battery’s effective capacity [13].
Charging speed, measured in C-rates, is another critical factor in battery degradation.
The C-rate indicates how quickly a battery is charged relative to its capacity. Higher C-rates
lead to increased stress on the battery’s internal components, accelerating degradation,
especially when coupled with high temperatures and it is showed on picture 3.
Driving
Temperature
High
Temperature
Capacity fade
obviously
Low
Temperature
Aging is
moderate
Depth of
Discharge
(100%;X%)
(50%+X;50%-X)
Current
High Current
Low Current
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Picture 3: Battery temperature and Remaining Battery Capacity at different
charge cycles.
Experimental studies on the thermal runaway (TR) of lithium-ion batteries have shown
low repeatability and involve certain risks, requiring significant human and material
resources. Furthermore, these studies are economically inefficient as they only provide
limited observations of surface phenomena during the experimental process. In order to
overcome these limitations, researchers have turned to numerical simulation software to
simulate the thermal runaway process of lithium-ion batteries. The failure rate is estimated to
be 1 in 40 million if LIB are stored and operated within the conditions recommended by
manufacturers [14]. However, unforeseen circumstances such as overcharging, external
heating and poor mechanical handling can significantly increase this failure probability.
Although various safety devices have been integrated into commercial LIB packs, failures have
occurred in many cells used in various fields, leading to accidents [15].
V. Conclusion
The widespread adoption of electric vehicles hinges significantly on the performance
and reliability of lithium-ion batteries. Among various battery technologies, the Blade Battery,
a lithium iron phosphate (LFP)-based system, stands out due to its structural innovations that
enhance energy density, improve safety, and streamline thermal management. However, like
all Li-ion batteries, Blade Batteries are susceptible to degradation, particularly under severe
thermal conditions, which can negatively affect efficiency, longevity, and operational safety.
This review has examined key factors influencing battery degradation, including heat
generation, charging speeds, environmental conditions, and depth of discharge. High
temperatures, especially above 40°C, were found to accelerate battery aging by promoting
solid-electrolyte interphase (SEI) layer growth and lithium plating, leading to capacity fade.
Similarly, excessive charging rates (high C-rates) increase internal stress, reducing the
lifespan of battery cells. The integration of advanced thermal management systems is,
therefore, essential to regulate battery temperatures and mitigate degradation risks. The
Blade Battery’s unique design, which eliminates traditional module structures and optimizes
40
50
60
70
80
90
100
20
25
30
35
40
45
50
Rema
ini
ng
Ba
tt
er
C
ap
acit
y
(%)
Battery Temperature (oC)
100 Charge Cycle
200 Charge Cycle
300 Charge Cycle
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internal space, enables higher energy density while enhancing heat dissipation. This
structural innovation allows for a more compact and efficient battery pack, reducing
unnecessary weight and improving the overall performance of electric vehicles. However,
while Blade Batteries offer significant advantages in endurance and safety, they still require
robust thermal management strategies to prevent degradation, particularly in extreme
environmental conditions. As electric vehicle adoption continues to grow globally, further
research is necessary to refine battery thermal management techniques and develop
enhanced materials that offer greater thermal stability. Additionally, improvements in battery
manufacturing, predictive maintenance, and charging infrastructure will play a crucial role in
ensuring the long-term reliability and sustainability of electric vehicle battery systems. Future
studies should also explore the integration of artificial intelligence and machine learning
techniques for real-time battery monitoring and predictive analytics, helping to optimize
battery life and prevent premature failure. Ultimately, the findings in this review underscore
the importance of designing electric vehicle batteries that balance high energy efficiency with
durability and safety, ensuring sustainable advancements in the transportation sector.
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