Detailed Characterization and Parameterization of a Large State-of-the-Art Commercial Li-Ion Pouch Cell: Part I. Cell Characterization

Advancing lithium-ion battery technology requires detailed insights into cell performance, chemistry, and design—yet such information is scarce for commercial cells. This study presents the comprehensive characterization of a 64 Ah lithium-ion pouch cell optimized for power applications. Cell-level testing included charge and discharge capacities, dQ/dV and dV/dQ profiles, and open-circuit-potentials across the entire state-of-charge range. Thermal behavior was assessed via temperature-dependent capacity and resistance measurements, and entropy spectroscopy. Rate capability and corresponding temperature evolution were evaluated, alongside safety assessments. Statistical analysis of 140 cells showed consistent initial capacities of 65.94 Ah ± 0.64%. Cell-teardown provided insights into internal architecture: 52 cathode and 53 anode sheets with an areal capacity of 2.3 mAh cm −2 . Active materials were NMC532/graphite with an EC:DMC:EMC electrolyte blend and an Al 2 O 3 -coated polypropylene separator. Pouch and tabs were also characterized. This work is the first part of a series of papers contributing to the understanding of properties and design of state-of-the-art cells, support modelling across several levels, and setting the benchmark for further work on ageing, degradation and safety on this cell. Upcoming parts will focus on the in-depth characterization of the electrodes followed by the compilation of the collected data into a full P2D model parameter set.