Cylindrical vs Pouch battery cells?

Hey everyone,

I'm in the Top Dutch Solar Racing and we're debating as to what type of bettery to use for our car. I'd love to get some insight from those with expereince in high-performance battery design or just anyone with some insight! We've made our decision but I'm still debating between the benefits and downfalls of cylindrical vs. pouch cells for our next-gen pack, and each has trade-offs.

From my perspective:

  • Cylindrical cells have a great track record in terms of thermal stability and mechanical durability. They're easier to manage in terms of cooling, and the standardized form factor makes assembly more predictable. However, they tend to take up more space and require extra structural reinforcement.

  • Pouch cells offer higher energy density per unit volume and can be packed more efficiently into our available space. However, they're more sensitive to swelling, and ensuring proper mechanical protection in a lightweight race car is challenging.

Given that weight, energy density, and reliability are all critical for us, I'm curious - what has been your experience or your opinion with these cell types in high-performance applications? How do you approach cooling and mechanical protection, especially for pouch cells?

Looking forward to hearing your thoughts!

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