Experimental Thermal Assessment of Novel Dual-Terminal Architecture for Cylindrical Li-Ion Battery Packs Under Variable Discharge Rates

A novel architectural design is proposed to optimize the thermal management of lithium-ion batteries (LiBs) through a software-enabled switching mechanism. This approach addresses critical challenges such as hot-spot generation, peak temperature rise, and uneven thermal distribution—issues commonly observed in conventional single-terminal battery modules (STBMs). The proposed dual-terminal configuration integrates an enhanced battery pack structure with a software-enabled switching algorithm that identifies the 50% depth of discharge (DoD) and toggles the current path between two terminals to supply the load. Correspondingly, the module also incorporates the division of four thermal zones and four regions concept in the battery module (BM). Experiments were conducted to evaluate the performance of the proposed model at five different C-rates: 0.5C, 0.75C, 1C, 1.25C, and 1.5C. The results demonstrate that the software-enabled dual-terminal switching (Se-DTS) consistently outperforms the STBM across three key aspects. First, in terms of peak temperature, Se-DTS achieved reductions of 19.33%, 17.83%, and 12.72% at C-rates of 1C, 1.25C, and 1.5C, respectively. Second, in thermal distribution, Se-DTS improved performance, with an 86.1% reduction at 1.25C. Third, regarding hot-spot reduction, improvements of 100% (regional level) and 72.22% (zonal level) were observed at 1.25C, while at 1.5C, an 80% improvement was achieved at the zonal level, without using a cooling system.