Chao-Yang Wang’s research while affiliated with Pennsylvania State University and other places

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Publications (287)


High heat-tolerance and safety of lithium metal batteries using a high-concentration phase-change electrolyte
  • Article

February 2025

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7 Reads

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1 Citation

Journal of Power Sources

Kaiqiang Qin

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Shanhai Ge

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Nitesh Gupta

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[...]

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Chao-Yang Wang




Internally actuated self-heating battery (iSHB) structure with two current-carrying terminals: concept and schematic
a Comparison between the conventional battery and the self-heating battery (SHB). Classical batteries are designed and operated as primarily passive devices with little control over their performance state, which depends strongly on temperature. Heating large cells necessary for electric vehicles is limited to slow external heating due to issues of spatial temperature non-uniformity. By adding an internal thermal actuator, battery temperature can be rapidly and uniformly modulated to activate the interfaces and boost power only when needed. b Battery power relative to that at 25 °C vs. temperature. Relative power is calculated as DCR25°C/DCR where DCR is the direct current resistance estimated from battery testing (Supplementary Fig. 1). The self-heating structure widens the performance window, whether it be for low-temperature performance recovery7,9 or enabling fast charging10–13. c Comparison between (left) the legacy SHB structure controlled by an external switch and (right) our iSHB structure based on an embedded field effect transistor (FET) switch (made by Dr. Kaiqiang Qin). d Heat capacity of a cell per °C temperature rise vs. cell size for 40 and −30 °C. The heat absorption capacity of a cell (250 Wh kg⁻¹) far exceeds the heat generated by a FET of practical resistance (0.5 mΩ), making internal switching and transistor cooling feasible (see Methods for calculation). The inset of (d) depicts the internal FET generating heat that is dissipated to the surrounding cell, which requires heat for warming.
Transistor-to-cell cooling efficacy
a, b FET and PCB temperature evolution during in situ and ex situ operation for heating from 23 °C to 60 °C and − 30 °C to 5 °C, respectively. In situ, the large thermal sink of the cell prevents high FET temperature, which otherwise would rise rapidly toward safety limits. c Effective thermal resistance between the PCB/FET and thermal sink (ambient air for ex situ and cell average temperature for in situ). Here, T∞ represents the effective heat sink temperature. TFET and TPCB represent the top and bottom heating sheet surface temperatures at the location of the FET, respectively. Ttop and Tbottom represent the top and bottom cell surface temperatures in the center of the cell. The inset illustrates the heating sheet embedded in the center of the cell, where TPCB is measured on the underside of the FET. See the Methods section for analysis details. Embedding the FET in the cell provides an order of magnitude reduction in thermal resistance to enable rapid and mutual thermal management for both the cell and FET. d Simulated temperature evolution during heating from 23 to 60 °C for a thermally optimized iSHB where the FET is in direct thermal contact with battery materials. e Effective thermal resistance for the cases in a and d. The simulation suggests direct thermal contact between the FET and battery materials can achieve an additional ten-fold reduction in thermal resistance. f Heat sink volume vs. thermal resistance off-the-shelf heat sinks that suit one of the most common power FET packages (TO-220) available from the two of the largest electronics distributors. The prototype iSHB cooling performance is comparable to these commercial circuit board FET heat sinks with a similar volume, and the simulation suggests even higher power dissipation is possible for the same allowable FET-to-cell temperature difference. Thus, using the battery as the heat sink could roughly halve the total system volume otherwise.
ISHB heating performance
a Cell voltage and heating current evolution during heating from − 40 °C to a cutoff temperature of 5 °C. b Temperature evolution of nickel foil (TNi), top cell surface (Ttop), bottom cell surface (Tbottom), and average cell surface (Taverage) during heating from − 40 °C. The inset illustrates the location of thermocouples (Ttop and Tbottom) and the heating element (TNi), where the average data plotted consists of only Ttop and Tbottom. c, d, e and f Respectively, average discharge heating current in C-rate, theoretical and experimental heating rates, energy/capacity consumption per °C of heating, and heating efficiency vs. ambient temperature. The theoretical heating rate is calculated with Eq. 3 based on the experimental heating current while the theoretical heating energy consumption is calculated by Eq. 1. The heating efficiency in f is determined by the ratio of theoretical to experimental energy consumption, as shown in Eq. 22 in the Methods section.
ISHB robustness: thermal and electrochemical cycling
a Cell voltage and temperature evolution during 10 repetitive heating cycles (activations) before the cell is recharged. b Capacity retention and heating time (τACT) normalized to that at cycle 0 vs. the number of activation cycles. 1000 heating cycles induces moderate capacity fade (∼ 7%) along with a degradation rate corresponding to ∼ 7% increase in heating time. c Capacity retention vs. cycle number during electrochemical cycle aging (charge and discharge with no heating). d Cell voltage vs. discharge capacity (C) normalized to that at cycle 0 for repetitive heating and cycle aging tests. Here, N represents the cycle number after which the capacity check was performed. Whether discharge is achieved conventionally or through self-heating, the rate of degradation is moderate, and no distinct abnormalities are observed during discharge.
Battery electronification: intracell actuation and thermal management
  • Article
  • Full-text available

June 2024

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70 Reads

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5 Citations

Electrochemical batteries – essential to vehicle electrification and renewable energy storage – have ever-present reaction interfaces that require compromise among power, energy, lifetime, and safety. Here we report a chip-in-cell battery by integrating an ultrathin foil heater and a microswitch into the layer-by-layer architecture of a battery cell to harness intracell actuation and mutual thermal management between the heat-generating switch and heat-absorbing battery materials. The result is a two-terminal, drop-in ready battery with no bulky heat sinks or heavy wiring needed for an external high-power switch. We demonstrate rapid self-heating (∼ 60 °C min⁻¹), low energy consumption (0.138% °C⁻¹ of battery energy), and excellent durability (> 2000 cycles) of the greatly simplified chip-in-cell structure. The battery electronification platform unveiled here opens doors to include integrated-circuit chips inside energy storage cells for sensing, control, actuating, and wireless communications such that performance, lifetime, and safety of electrochemical energy storage devices can be internally regulated.

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(Keynote) Rapid Thermal Management for Fast Charging of Energy-Dense Lithium-Ion Batteries

December 2023

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28 Reads

ECS Meeting Abstracts

Charging time trauma refers to the pain experienced by electric vehicle (EV) owners when the ‘refill’ time is significantly longer than that of traditional internal combustion engine vehicles. Worsening this trauma is the inconsistency of EV charging; for example, the same EV may take five times longer to charge on a cold day. Faster charging will alleviate this pain point and aid in the mass adoption of EVs, crucial for meeting near-term carbon emission goals. Reaching this goal will require smarter and more rapid thermal management to provide significantly faster safe charging. The results from the 2022 Nature article “Fast charging of energy-dense lithium-ion batteries” (DOI 10.1038/s41586-022-05281-0) where 265 Wh/kg lithium-ion pouch cells were charged from 0-70% in less than 12 minutes, 2,000 times in a row before end-of-life, will be presented. These cells used only proven materials, including a liquid electrolyte made from industrially-used components, and energy-dense, EV-grade electrodes. Key to success was smart cell thermal management. More recent advancements, including multi-cell battery-level data, will also be discussed. Figure 1


Challenges and Innovations of Lithium-Ion Battery Thermal Management Under Extreme Conditions: A Review

March 2023

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331 Reads

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23 Citations

ASME Journal of Heat and Mass Transfer

Thermal management is critical for safety, performance, and durability of lithium-ion batteries that are ubiquitous in consumer electronics, electric vehicles (EVs), aerospace, and grid-scale energy storage. Toward mass adoption of EVs globally, lithium-ion batteries are increasingly used under extreme conditions including low temperatures, high temperatures, and fast charging. Furthermore, EV fires caused by battery thermal runaway have become a major hurdle to the wide adoption of EVs. These extreme conditions pose great challenges for thermal management and require unconventional strategies. The interactions between thermal, electrochemical, materials, and structural characteristics of batteries further complicate the challenges, but they also enable opportunities for developing innovative strategies of thermal management. In this review, the challenges for thermal management under extreme conditions are analyzed. Then, the progress is highlighted in two directions. One direction is improving battery thermal management systems based on the principles of heat transfer, which are generally external to Li-ion cells. The other direction is designing novel battery structures, which are generally internal of Li-ion cells such as smart batteries with embedded sensors and actuators. The latter approach could greatly simplify or even eliminate the need for battery thermal management under extreme conditions. New research integrating these two approaches is recommended.


In Situ Measurement of Current Distribution in Large-Format Li-Ion Cells

March 2023

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61 Reads

Non-uniform current distributions in large-format Li-ion cells can cause underutilization of active materials, reduction of usable energy density, non-uniform heat generation, exacerbated lithium plating, and accelerated degradation. In situ measurements of current distributions in large-format Li-ion cells not only reveal local behaviors but also provide spatially resolved data for validation of electrochemical-thermal coupled models. The insights and models aid the development of faster rechargeable, energy denser, safer, and more durable Li-ion batteries. This work reviews the progress of in situ measurement of current distribution over the electrode area for large-format Li-ion cells. Direct measurement using segmented cells, indirect measurement using embedded local potential tabs, and noninvasive diagnosis with magnetic resonance imaging are discussed. Key findings from the measurements are then summarized, such as the current distributions under various operating conditions and cell designs, and the effects of non-uniform current distributions on local state of charge and usable energy density. Finally, future research needs are proposed.


Citations (68)


... + 0.15 TO electrolyte cycled stably for >200 cycles at room temperature with 80% capacity retention. The as-assembled ALB cell after undergoing hot formation (40 °C) at initial cycles, exhibited extraordinary safety performance when operated under a cell pressure of 1.2 MPa respectively [90]. Similarly, the effect of LNO additive in a reduced concentration of tetraethylene glycol dimethyl ether (TEGDME) electrolyte was studied, where the half-cell configuration 2M of LiTFSI improved the C.E. due to the stability conferred by the Li 2 O to the SEI during cycling [91]. ...

Reference:

Demystifying the Potential of Anode-Less Alkali Metal Batteries: Uncovering the Role of Liquid and Solid Electrolyte Combinations
Enhanced salt content and stabilized bilayer passivation interphase toward long-life and high-safety anode-free lithium battery
  • Citing Article
  • November 2024

Materials Today Energy

... 1,2 However, the risks of fire and explosion have raised concerns among consumers and the market regarding the current commercial Li-ion batteries. 3,4 Solid-state lithium metal batteries (SSBs), characterized by high energy density and enhanced safety, are regarded as ideal next-generation electrochemical energy storage systems. 5,6 The key component of SSBs, solid-state electrolytes (SSEs), is the core of current research. ...

Quantification of Lithium Battery Fires in Internal Short Circuit
  • Citing Article
  • November 2024

ACS Energy Letters

... The increasing market demand for multifunctional and portable electronic products has driven their advancement toward miniaturization, light weight, and high integration, which is bound to exacerbate issues concerning heat dissipation and electromagnetic (EM) pollution [1][2][3][4][5]. Polymer-based films are excellent candidates for application in electronic products as thermal-conductive and microwave-absorptive materials in light of their advantages including light-weight, high strength, good flexibility, simple synthesis, easy molding, and excellent electrical insulation [6][7][8][9][10]. ...

Battery electronification: intracell actuation and thermal management

... Copyright © 2016, Springer Nature Limited. (d) Schematic diagram of the self-heating battery and the percentage of self-heating energy consumption at different temperatures to its electric energy [155]. Copyright © 2024, American Chemical Society. ...

Lithium Iron Phosphate Superbattery for Mass-Market Electric Vehicles
  • Citing Article
  • February 2024

ACS Energy Letters

... These include battery energy density, capacity, life, reliability, safety, decreased battery costs, increased battery charge rate, and improved range retention of the battery in cold weather [2]. Temperature plays a significant role in influencing all of these factors, making advanced battery thermal management (BTM) a crucial solution for optimizing battery performance [3][4][5][6][7]. ...

Challenges and Innovations of Lithium-Ion Battery Thermal Management Under Extreme Conditions: A Review
  • Citing Article
  • March 2023

ASME Journal of Heat and Mass Transfer

... Lithium-ion batteries (LIBs) are currently the most ideal options, offering an energy density of ~ 250 Wh/kg [5][6][7][8] . However, further advancements are urgently needed to extend the cruising range of these applications [9][10][11][12][13] . Recently, rechargeable lithium-chlorine batteries using thionyl chloride (SOCl 2 ) as the electrolyte, Li metal as the anode, and porous materials as the cathode have gathered much attention due to their high theoretical energy density [14][15][16][17][18][19][20][21][22][23] . ...

Fast charging of energy-dense lithium-ion batteries

Nature

... A larger single sheet foil area, A foil , directly leads to a reduction in the internal resistance of a single electrochemical sandwich, and a greater shorting current. Further, it has previously been demonstrated that a larger nail diameter, D nail , leads to more global heating, due to its larger thermal mass to absorb I 2 R short heating and an enhanced ability to reject heat axially through the nail (Shaffer et al., 2012;Kalupson et al., 2014;Zhao et al., 2015a). Generally speaking, for a given cell internal structure (electrode thicknesses, porosities, etc.), A foil and D nail largely determine the locality (global, local, or mixed) of the heating, and a greater cell capacity accentuates the local or global nature of the heating, simply by having greater energy to be dissipated during the short. ...

Cell- and Pack-Level Simulation of Large-Format Li-Ion Battery Safety Events
  • Citing Article
  • April 2014

ECS Meeting Abstracts

... The high use of lithium-ion cells (LIBs) in various mobile equipment [1] and, in particular, in the development and commercial implementation of electrical cars [2,3] has made this technology progress rapidly in recent years, becoming the predominant choice in terms of rechargeable batteries. Besides their intense use for consumer electronics and electrical cars, LIBs have also been employed intensively in energy storage systems [4], grid services [5,6], UPS systems [7], electrified aviation [8,9], and even in tailored designed batteries for aerospace [10] or military applications [11]. In comparison with similar rechargeable technologies, such as nickel-cadmium, nickel-metal-hydride, or lead-acid types, lithium-ion cells (LIBs) have some particular advantages. ...

Next-Generation Aviation Li-Ion Battery Technologies—Enabling Electrified Aircraft
  • Citing Article
  • September 2022

The Electrochemical Society Interface

... Most of the literature analyzes eVTOL feasibility from an engineering perspective, proving that eVTOL aircraft can operate under certain technical conditions [25][26][27][28][29][30][31]. However, economic feasibility relies on mathematical modeling [32][33][34][35][36][37][38]. ...

Advancements in extreme fast charging to foster sustainable electrification
  • Citing Article
  • March 2022

One Earth

... FF-E exhibits lower HFR compared to FF-B and this difference is more pronounced at low RH conditions. The observed outcomes are in accordance with the deeper cathode channels of FF-E, which results in a lower gas velocity and thus in an increased water retention [22,67]. This phenomenon is particularly notable at low RH gas reactants, where the increased water retention significantly enhances membrane hydration and consequently increases ion conductivity [68], leading to the differences in results observed in Fig. 11a. ...

Modeling liquid water re-distributions in bi-porous layer flow-fields of proton exchange membrane fuel cells

Journal of Power Sources