Academic Journal of Engineering and Technology Science, 2026, 9(3); doi: 10.25236/AJETS.2026.090317.
Chen Li1,2,3, Shuoyuan Mao3, Yuebo Yuan5,6, Ziding Wang3, Yong Peng3, Yukun Sun5,6, Depeng Wang 5,6, Cheng Zhu6, Caijuan Xia1, Xiaodan Wang4, Yao Lu2
1School of Science, Xi'an University of Technology, Xi'an, 710600, China
2Beijing Institute of Nanoenergy and Nanosystems, Chinese Academy of Sciences, Beijing, 101400, China
3School of Vehicle and Mobility, Tsinghua University, Beijing, 100084, China
4China Astronaut Research and Training Center, Beijing, 100094, China
5Faculty of Quality Management and Inspection & Testing, Yibin University, Yibin, 644000, China
6Key Laboratory of Energy Storage and Power Battery Safety, State Administration for Market Regulation, Yibin, 644004, China
Accurate potential measurement in three-electrode lithium-ion batteries remains challenging due to disturbances from embedded sensors. This work systematically investigates the effect of sensor geometry, specifically width and thickness, on measurement accuracy using membrane-based potential sensors integrated into commercial pouch cells. At low rates (0.33 C and 1 C), reducing sensor dimensions significantly improves accuracy, yielding negative electrode potentials closer to 0 V (vs. Li/Li⁺) and enabling more conservative determination of the lithium plating boundary. At a high rate of 2 C, however, strong polarization and concentration gradients induce signal fluctuations, weaken stratification, and even cause trend reversal, revealing fundamental accuracy limitations. These findings quantitatively demonstrate the trade-off between sensor invasiveness and measurement fidelity, and provide clear design guidelines: thinner substrates and narrower active regions are preferred to minimize disturbance. This work advances the understanding of sensor-induced errors in three-electrode systems and supports safer battery management through more reliable lithium plating detection under practical operating conditions.
Flexible potential sensors; Lithium-ion batteries; Three-electrode system; Geometric dimension effect; Measurement accuracy
Chen Li, Shuoyuan Mao, Yuebo Yuan, Ziding Wang, Yong Peng, Yukun Sun, Depeng Wang, Cheng Zhu, Caijuan Xia, Xiaodan Wang, Yao Lu. Embedded Flexible Potential Sensors for Safety Monitoring of Lithium-Ion Batteries. Academic Journal of Engineering and Technology Science (2026), Vol. 9, Issue 3: 127-138. https://doi.org/10.25236/AJETS.2026.090317.
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