Thermal–Electrical Optimization of Lithium-Ion Battery Conductor Structures Under Extreme High Amperage Current

This study addresses the critical challenges of conductor structure fusing, thermal management failure, and thermal runaway risks in lithium-ion batteries under extreme high-amperage discharge conditions. By integrating theoretical analysis, multiphysics coupling simulations, and experimental validation, the research systematically investigates the overcurrent capability of lithium battery conductor structures. A novel current–thermal structure coupled finite element model was developed to analyze the dynamic relationship between key parameters, specifically overcurrent cross-sectional area and contact area, and their influence on temperature gradient distribution. Experimental results confirm the model’s accuracy, revealing that under extreme high-amperage conditions, increasing the conductor cross-sectional area by 50% only marginally extends the battery’s current-carrying duration from 0.75 s to 0.8 s. This limited enhancement is attributed to rapid heat generation, which restricts the effectiveness of increasing the cross-sectional area alone. Instead, optimizing the conductor structure by modifying the heat conduction path, which involves a similar increase in the cross-sectional area and an additional 60% increase in contact area through the addition of a welding reinforcement structure, achieves thermal equilibrium. The optimized design achieves a current-carrying duration of 1.73 s, which is 230% of the duration of the traditional configuration. This work establishes a scalable framework for enhancing the thermal–electrical performance of lithium-ion batteries, providing a theoretical foundation for structural optimization and offering significant methodological support for advancing research in high-power battery design, with potential applications in electric vehicles, renewable energy systems, and industrial robotics.