Advanced Coupled Electrochemical-Thermal Simulations of 4680 Cylindrical Cells on a Pseudo-Four-Dimensional Grid

This work presents a fully coupled electrochemical-thermal simulation of 4680 cylindrical cells using a pseudo-four-dimensional (P4D) continuum model in BattMo. The model captures detailed jelly roll dynamics, showing that continuous-tab designs reduce ohmic losses and peak temperatures by 12°C at 2C discharge, improving performance and safety. Simulated specific energy (223.6 Wh/kg) and energy density (615.0 Wh/L) align within ±3\% of experimental values. The study highlights electrolyte transport limitations as a key factor in high-rate performance and introduces adjoint-based optimization for parameter tuning. These insights provide a foundation for improving large-format battery designs.