The thermal mechanics of Lithium-ion (Li-ion) batteries is explored with a focus on thermal swelling. Experiments show for the first time that the swelling shape of prismatic battery cells due to temperature variations is significantly different from that due to Li-ion intercalation in unconstrained conditions. In contrast to uniform and orthotropic Li-ion intercalation swelling in a direction perpendicular to electrodes, the nonuniform temperature distribution in the jellyroll and the gaps/voids between electrodes result in distinguishable different swelling shapes. A unique coupled thermal-structural analysis with a simple, but efficient 3-D finite numerical model is proposed to investigate the impact of temperature variations on the thermal behaviors of battery cells. Anisotropic heat conduction and temperature dependency of the coefficient of thermal expansion are taken into account and found to have an impact on temperature distribution and thermal expansion. Experimental validation of the proposed model clearly demonstrates that the coupled thermal-structural analysis with the proposed model can predict accurately the thermal swelling at unconstrained conditions. The solution at pack (constrained) conditions shows that the nonuniform temperature distribution of the jellyroll still plays a critical role for the thermal swelling shape, although the gaps/voids do not occur because of the constraints from spacers in the pack, suggesting that the estimation of core temperature is important. Such an accurate model, able to estimate cell thermal behavior, is beneficial to the design of Li-ion batteries, development of stress or strain sensors, optimum sensor placement, and thermal management of not only single battery cells but also battery packs. (C) 2016 Elsevier Ltd. All rights reserved.