Coupled electro-thermal-aging battery pack modeling - Part 2: Multi-node module level

Current battery module design tools typically trade off fidelity for computational cost, limiting their use to early and intermediate design stages. This work presents a mid-fidelity, multiphysics electro-thermal modeling framework for battery modules that incorporates aging effects, enabling both component-level sizing and the design of safe, integrated architectures. The model is fully parametric and captures key electro-thermal and degradation mechanisms within a semi-empirical formulation. The model was validated experimentally at both cell and module scales using a commercially available module. It provides predictions of electrical state, temperature, and state of health in both space and time while maintaining high computational efficiency, with full charge simulations completed in seconds and year-long high-intensity operation simulated in less than four hours. The capabilities of the framework are demonstrated through three representative case studies: (1) the influence of C-rate on module electro-thermal behavior, (2) the propagation of cell-level electrical and thermal variations to module-level performance, and (3) the evolution of thermal imbalance driven by aging over the module lifecycle. By consolidating and extending prior mid-fidelity modeling approaches into a unified framework, this work provides a practical and scalable tool for battery engineers. The model supports key design and analysis tasks, including architecture definition, thermal management development, cell selection, defect sensitivity assessment, and operation optimization for reduced aging.