Beyond the cell development: A geometry- and material-driven framework for battery module modeling and performance evaluation

This paper introduces an open-source framework for modeling battery modules, enhancing the existing ISEA Cell and Pack Designer through geometry- and material-driven approaches. The framework automates the dimensioning and shaping of module components based on specified boundary conditions while evaluating key electrical and physical parameters. A finite-volume discretization method is utilized to accurately calculate connection and module resistances. Validation was performed by assembling a cylindrical sodium-ion battery module using framework data and conducting a top-down analysis of prismatic and pouch automotive modules obtained from teardown evaluations. Resulting in high accuracy, with deviations of less than 3% for most parameters when comparing the model to the measured data. This framework streamlines prototyping, enabling quick modeling and CAD data export for comprehensive simulations, sensitivity analyses, and life cycle assessments. Furthermore, the paper illustrates the construction of a cylindrical sodium-ion module using CAD data generated by the framework, showcasing its practical applications and benefits in battery module design and evaluation.