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<p>The mechanical properties and failure behavior of batteries are critical to ensuring the crash safety of vehicles. This study provides a comprehensive experimental investigation of the damage patterns and residual functionality of vehicular lead-acid batteries through fragment impact tests at varying impact velocities. Three different levels of the battery, i.e., the entire battery, the single battery cell, and the single electrode plate assembly, are considered to study the mechanical behavior at different scales. The effects of fragment impact location, hole size, and impact velocity on the residual functionality of the battery are discussed. The degree of battery damage is characterized by its voltage and residual capacity after impact. Measurements of voltage and capacity are taken immediately after impact, 40&#xa0;min post-impact, and 24&#xa0;h after impact. The results reveal that batteries exhibit three typical structural damage patterns and two performance degradation scenarios after fragment impact. When the fragment impact velocity exceeds 1331.7&#xa0;m/s, the battery voltage drops below 11&#xa0;V (End-of-Discharge Voltage), preventing the battery from initiating vehicle startup. Similarly, when the impact velocity exceeds 1232.2&#xa0;m/s, the battery’s residual capacity falls below 40%, indicating complete failure. The influence of the fragment’s impact angle and impact position on battery damage is relatively limited.</p>

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Dynamic Failure Analysis of Vehicular Lead-Acid Batteries under High-Velocity Impact

  • 期刊论文

  • 发表日期：

    2026年7月31日

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  • Cheng Zhang,
  • Zhibin Li,
  • Yong Peng,
  • Xiangyu Li

摘要

The mechanical properties and failure behavior of batteries are critical to ensuring the crash safety of vehicles. This study provides a comprehensive experimental investigation of the damage patterns and residual functionality of vehicular lead-acid batteries through fragment impact tests at varying impact velocities. Three different levels of the battery, i.e., the entire battery, the single battery cell, and the single electrode plate assembly, are considered to study the mechanical behavior at different scales. The effects of fragment impact location, hole size, and impact velocity on the residual functionality of the battery are discussed. The degree of battery damage is characterized by its voltage and residual capacity after impact. Measurements of voltage and capacity are taken immediately after impact, 40 min post-impact, and 24 h after impact. The results reveal that batteries exhibit three typical structural damage patterns and two performance degradation scenarios after fragment impact. When the fragment impact velocity exceeds 1331.7 m/s, the battery voltage drops below 11 V (End-of-Discharge Voltage), preventing the battery from initiating vehicle startup. Similarly, when the impact velocity exceeds 1232.2 m/s, the battery’s residual capacity falls below 40%, indicating complete failure. The influence of the fragment’s impact angle and impact position on battery damage is relatively limited.