Direct access to internal temperature readings in lithium-ion batteries provides the opportunity to infer physical information to study the effects of increased heating, degradation, and thermal runaway. In this context, a method to insert temperature sensors into commercial 18650 cells to determine the short- and long-term effects through characterization testing is developed. Results show that sensor insertion only causes a decrease in capacity of 0.5-2.3%, and an increase in DC resistance of approximately 15 mΩ. The temperatures of the modified cells are approximately 0.5 °C higher than the control cells, the difference between the internal and external temperature readings of the modified cells is approximately 0.4 °C, and the modified cells exhibit the same temperature behavior and trend during cycling as the control cells. The cells are able to operate and collect data for 100-150 cycles before their capacities fade and resistances increase beyond what is observed in the control cells. The results of the testing show that cells modified with internal temperature sensors provide useful internal temperature data for cells that have experienced little or no cyclic aging.
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