Electrolyte Volume Effects on Electrochemical Performance and Solid Electrolyte Interphase in Si-Graphite/NMC Lithium-Ion Pouch Cells

Failure of Lithium-Ion Batteries Accelerated by Gravity

The safety concerns surrounding lithium-ion batteries (LIBs) have garnered increasing attention due to their potential to endanger lives and incur significant financial losses. However, the origins of battery failures are diverse, presenting significant challenges in developing safety measures to mitigate accidental catastrophes. In this study, the aging mechanism of LiNi0.5Co0.2Mn0.3O2||graphite-based cylindrical 18,650 LIBs stored at room temperature for two years was investigated. It was found that an uneven distribution of electrolytes can be caused by gravity, leading to temperature variations within the battery. Specifically, it was observed that the temperature at the top of the battery was approximately -0.89 °C higher than at the bottom, correlating with an increase in partial internal resistance. Additionally, upon disassembly and analysis of spent batteries, the most significant damage to electrode materials at the top of the battery was observed. These findings suggest that gravity-induced electrolyte insufficiency exacerbates side reactions, particularly at the top of the battery. This study offers a unique perspective on the safety concerns associated with high-energy-density batteries in long-term and large-scale applications.

Tailoring the Size of Reduced Graphene Oxide Sheets to Fabricate Silicon Composite Anodes for Lithium-Ion Batteries

The integration of a silicon (Si) anode into lithium-ion batteries (LIBs) holds great promise for energy storage, but challenges arise from unstable electrochemical reactions and volume changes during cycling. This study investigates the influence of reduced graphene oxide (rGO) size on the performance of rGO-protected Si composite (Si@rGO) anodes. Two sizes of graphene oxide (GO(L) and GO(S)) are used to synthesize Si@rGO composites with a core-shell structure by spray drying and thermal reduction. Electrochemical evaluations show the advantages of the Si@rGO(S) anode with improved cycle life and cycling efficiency over Si@rGO(L) and pure Si. The Si@rGO(S) anode facilitates the formation of a stable LiF-rich solid electrolyte interface (SEI) after cycling, ensuring enhanced capacity retention and swelling control. Rate capability tests also demonstrate the superior high-power performance of Si@rGO(S) with low and stable resistances in Si@rGO(S) over extended cycles. This study provides critical insights into the tailoring of graphene-protected Si composites, highlighting the critical role of rGO size in shaping structural and electrochemical properties. The Si material wrapped by graphene with an optimal lateral size of graphene emerges as a promising candidate for high-performance LIB anodes, thereby advancing electrochemical energy storage technologies.

Si Nanowires: From Model System to Practical Li-Ion Anode Material and Beyond

Nanowire (NW)-based anodes for Li-ion batteries (LIBs) have been under investigation for more than a decade, with their unique one-dimensional (1D) morphologies and ability to transform into interconnected active material networks offering potential for enhanced cycling stability with high capacity. This is particularly true for silicon (Si)-based anodes, where issues related to large volumetric expansion can be partially mitigated and the cycle life can be enhanced. In this Perspective, we highlight the trajectory of Si NWs from a model system to practical Li-ion battery anode material and future prospects for extension to beyond Li-ion batteries. The study examines key research areas related to Si NW-based anodes, including state-of-the-art (SoA) characterization approaches followed by practical anode design considerations, including NW composite anode formation and upscaling/full-cell considerations. An outlook on the practical prospects of NW-based anodes and some future directions for study are detailed.

Harmless pre-lithiation via advantageous surface reconstruction in sacrificial cathode additives for lithium-ion batteries

Sacrificial cathode additives have emerged as a tempting strategy to compensate the initial capacity loss (ICL) in Li-ion batteries (LIBs) manufacturing. However, the utilization of sacrificial cathode additives inevitably brings residuals, side reactions, and negative impacts in which relevant researches are still in the early stage. In this study, we conduct a systematic investigation on the effects of employing a nickel-based sacrificial additive, Li2Cu0.1Ni0.9O2 (LCNO), and propose a feasible strategy to achieve advantageous surface reconstruction on LCNO. Specifically, we build a Li5AlO4 (LAO) coating layer on the LCNO through dry ball milling and annealing treatment. This process not only consumes surface residual lithium compounds on LCNO but also demonstrates minimal detrimental effects on its performance. The surface reconstructed LCNO (SR-LCNO) reveals mitigated gas generation and suppressed structure degradation under high working voltage (＞4.1 V), thereby causing negligible negative effects on the cycling capability and rate performance of commercial cathode materials. The full cells containing SR-LCNO deliver significantly improved electrochemical properties, with no observed exacerbation of side reactions. This work awakes the awareness of the prudent utilization of sacrificial cathode additives and provides an effective strategy for harmless pre-lithiation via surface reconstructed sacrificial cathode additives.

Hollow-core optical fibre sensors for operando Raman spectroscopy investigation of Li-ion battery liquid electrolytes

Improved analytical tools are urgently required to identify degradation and failure mechanisms in Li-ion batteries. However, understanding and ultimately avoiding these detrimental mechanisms requires continuous tracking of complex electrochemical processes in different battery components. Here, we report an operando spectroscopy method that enables monitoring the chemistry of a carbonate-based liquid electrolyte during electrochemical cycling in Li-ion batteries with a graphite anode and a LiNi_0.8Mn_0.1Co_0.1O₂ cathode. By embedding a hollow-core optical fibre probe inside a lab-scale pouch cell, we demonstrate the effective evolution of the liquid electrolyte species by background-free Raman spectroscopy. The analysis of the spectroscopy measurements reveals changes in the ratio of carbonate solvents and electrolyte additives as a function of the cell voltage and show the potential to track the lithium-ion solvation dynamics. The proposed operando methodology contributes to understanding better the current Li-ion battery limitations and paves the way for studies of the degradation mechanisms in different electrochemical energy storage systems.

Epitaxial growth of an atom-thin layer on a LiNi0.5Mn1.5O4 cathode for stable Li-ion battery cycling

Transition metal dissolution in cathode active material for Li-based batteries is a critical aspect that limits the cycle life of these devices. Although several approaches have been proposed to tackle this issue, this detrimental process is not yet overcome. Here, benefitting from the knowledge developed in the semiconductor research field, we apply an epitaxial method to construct an atomic wetting layer of LaTMO₃ (TM = Ni, Mn) on a LiNi_0.5Mn_1.5O₄ cathode material. Experimental measurements and theoretical analyses confirm a Stranski-Krastanov growth, where the strained wetting layer forms under thermodynamic equilibrium, and it is self-limited to monoatomic thickness due to the competition between the surface energy and the elastic energy. Being atomically thin and crystallographically connected to the spinel host lattices, the LaTMO₃ wetting layer offers long-term suppression of the transition metal dissolution from the cathode without impacting its dynamics. As a result, the epitaxially-engineered cathode material enables improved cycling stability (a capacity retention of about 77% after 1000 cycles at 290 mA g^-1) when tested in combination with a graphitic carbon anode and a LiPF₆-based non-aqueous electrolyte solution.

Impact of Charge Voltage on Factors Influencing Capacity Fade in Layered NMC622: Multimodal X-ray and Electrochemical Characterization

Ni-rich NMC is an attractive Li-ion battery cathode due to its combination of energy density, thermal stability, and reversibility. While higher delivered energy density can be achieved with a more positive charge voltage limit, this approach compromises sustained reversibility. Improved understanding of the local and bulk structural transformations as a function of charge voltage, and their associated impacts on capacity fade are critically needed. Through simultaneous operando synchrotron X-ray diffraction (XRD) and X-ray absorption spectroscopy (XAS) of cells cycled at 3-4.3 or 3-4.7 V, this study presents an in-depth investigation into the effects of voltage window on local coordination, bulk structure, and oxidation state. These measurements are complemented by ex situ X-ray fluorescence (XRF) mapping and scanning electrochemical microscopy mapping (SECM) of the negative electrode, X-ray photoelectron spectroscopy (XPS) of the positive electrode, and cell level electrochemical impedance spectroscopy (EIS). Initially, cycling between 3 and 4.7 V leads to greater delivered capacity due to greater lithium extraction, accompanied by increased structural distortion, moderately higher Ni oxidation, and substantially higher Co oxidation. Continued cycling at this high voltage results in suppressed Ni and Co redox, greater structural distortion, increased levels of transition metal dissolution, higher cell impedance, and 3× greater capacity fade.

From Materials to Cell: State-of-the-Art and Prospective Technologies for Lithium-Ion Battery Electrode Processing

Electrode processing plays an important role in advancing lithium-ion battery technologies and has a significant impact on cell energy density, manufacturing cost, and throughput. Compared to the extensive research on materials development, however, there has been much less effort in this area. In this Review, we outline each step in the electrode processing of lithium-ion batteries from materials to cell assembly, summarize the recent progress in individual steps, deconvolute the interplays between those steps, discuss the underlying constraints, and share some prospective technologies. This Review aims to provide an overview of the whole process in lithium-ion battery fabrication from powder to cell formation and bridge the gap between academic development and industrial manufacturing.

The Effects of Gas Saturation of Electrolytes on the Performance and Durability of Lithium-Ion Batteries

Traces of species in batteries are known to impact battery performance. The effects of gas species, although often reported in the electrolyte and evolving during operation, have not been systematically studied to date and are therefore barely understood. This study reveals and compares the effects of different gases on the charge-discharge characteristics, cycling stability and impedances of lithium-ion batteries. All investigated gases have been previously reported in lithium-ion batteries and are thus worth investigating: Ar, CO₂ , CO, C₂ H₄ , C₂ H₂ , H₂ , CH₄ and O₂ . Gas-electrolyte composition has a significant influence on formation, coulombic and energy efficiencies, C-rate capability, and aging. Particularly, CO₂ and O₂ showed a higher C-rate capability and a decrease in irreversible capacity loss during the first cycle compared to Ar. Similar discharge capacities and aging behaviors are observed for CO, C₂ H₄ and CH₄ . Acetylene showed a large decrease in performance and cycle stability. Furthermore, electrochemical impedance spectroscopy revealed that the gases mainly contribute to changes in charge transfer processes, whereas the effects on resistance and solid electrolyte interphase performance were minor. Compared to all other gas-electrolyte mixtures, the use of CO₂ saturated electrolyte showed a remarkable increase in all performance parameters including lifetime.

Future Material Developments for Electric Vehicle Battery Cells Answering Growing Demands from an End-User Perspective

Nowadays, batteries for electric vehicles are expected to have a high energy density, allow fast charging and maintain long cycle life, while providing affordable traction, and complying with stringent safety and environmental standards. Extensive research on novel materials at cell level is hence needed for the continuous improvement of the batteries coupled towards achieving these requirements. This article firstly delves into future developments in electric vehicles from a technology perspective, and the perspective of changing end-user demands. After these end-user needs are defined, their translation into future battery requirements is described. A detailed review of expected material developments follows, to address these dynamic and changing needs. Developments on anodes, cathodes, electrolyte and cell level will be discussed. Finally, a special section will discuss the safety aspects with these increasing end-user demands and how to overcome these issues.

A facile and low-cost Al2O3 coating as an artificial solid electrolyte interphase layer on graphite/silicon composites for lithium-ion batteries

Graphite/silicon (G/Si) composites are considered as possible alternative anode materials to commercial graphite anodes. However, the unstable solid electrolyte interphase (SEI) on G/Si particles results in rapid capacity decay, impeding practical applications. Herein, a facile and low-cost Al₂O₃ coating was developed to fabricate stable artificial SEI layers on G/Si composites. The amorphous Al₂O₃ coating with a thickness of 10-15 nm was synthesized by a simple sol-gel method followed by high-temperature annealing. The Al₂O₃ coated G/Si anode delivers an initial discharge capacity of 540 mAh g^-1 at 25 °C and has improved Coulombic efficiency and cycling stability. After 100 cycles, the capacity retention is 76.4%, much higher than the 56.4% of the uncoated anode. Furthermore, the Al₂O₃ coating was found to be more effective at improving the stability of G/Si at a higher temperature (55 °C). This was explained by the Al₂O₃ coating suppressing the growth of SEI on Si/G and thus reducing the charge transfer resistance at the G/Si-electrolyte interface. It is expected that the Al₂O₃ coating prepared by the sol-gel process can be applied to other Si-based anodes in the manufacture of practical high-performance lithium-ion batteries.

Understanding Stabilization in Nanoporous Intermetallic Alloy Anodes for Li-Ion Batteries Using Operando Transmission X-ray Microscopy

Tin-based alloying anodes are exciting due to their high energy density. Unfortunately, these materials pulverize after repetitive cycling due to the large volume expansion during lithiation and delithiation; both nanostructuring and intermetallic formation can help alleviate this structural damage. Here, these ideas are combined in nanoporous antimony-tin (NP-SbSn) powders, synthesized by a simple and scalable selective-etching method. The NP-SbSn exhibits bimodal porosity that facilitates electrolyte diffusion; those void spaces, combined with the presence of two metals that alloy with lithium at different potentials, further provide a buffer against volume change. This stabilizes the structure to give NP-SbSn good cycle life (595 mAh/g after 100 cycles with 93% capacity retention). Operando transmission X-ray microscopy (TXM) showed that during cycling NP-SbSn expands by only 60% in area and then contracts back nearly to its original size with no physical disintegration. The pores shrink during lithiation as the pore walls expand into the pore space and then relax back to their initial size during delithiation with almost no degradation. Importantly, the pores remained open even in the fully lithiated state, and structures are in good physical condition after the 36th cycle. The results of this work should thus be useful for designing nanoscale structures in alloying anodes.

Encasing Prelithiated Silicon Species in the Graphite Scaffold: An Enabling Anode Design for the Highly Reversible, Energy-Dense Cell Model

Si anodes suffer from poor cycling efficiency because of the pulverization induced by volume expansion, lithium trapping in Li-Si alloys, and unfavorable interfacial side reactions with the electrolyte; the comprehensive consideration of the Si anode design is required for their practical deployment. In this article, we develop a cabbage-inspired graphite scaffold to accommodate the volume expansion of silicon particles in interplanar spacing. With further interfacial modification and prelithiation processing, the Si@G/C anode with an areal capacity of 4.4 mA h cm^-2 delivers highly reversible cycling at 0.5 C (Coulombic efficiency of 99.9%) and a mitigated volume expansion of 23%. Furthermore, we scale up the synthetic strategy by producing 10 kg of the Si@G/C composite in the pilot line and pair this anode with a LiNi_0.8Co_0.1Mn_0.1O₂ cathode in a 1 A h pouch-type cell. The full-cell prototype realizes a robust cyclability over 500 cycles (88% capacity retention) and an energy density of 301.3 W h kg^-1 at 0.5 C. Considering the scalable fabrication protocol, holistic electrode formulation design, and harmony integration of key metrics evaluated both in half-cell and full-cell tests, the reversible cycling of the prelithiated silicon species in the graphite scaffold of the composite could enable feasible use of the composite anode in high-energy density lithium batteries.

Thermal Runaway Triggered by Plated Lithium on the Anode after Fast Charging

Battery safety, at the foundation of fast charging, is critical to the application of lithium-ion batteries, especially for high energy density cells applied in electric vehicles. In this paper, an earlier thermal runaway of cells after fast charging application is illustrated. Under this condition, the reaction between the plated lithium and electrolyte is revealed to be the mechanism of thermal runaway triggering. The mechanism is proved by the accelerated rate calorimetry tests for partial cells, which determine the triggering reactions of thermal runaway in the anode-electrolyte thermodynamic system. The reactants in this system are analyzed by nuclear magnetic resonance and differential scanning calorimetry, proving that the vigorous exothermic reaction is induced by the interaction between the plated lithium and electrolyte. As a result, the finding of thermal runaway triggered by the plated lithium on anode surface of cells after fast charging promotes the understanding of thermal runaway mechanisms, which warns of the danger of plated lithium in the utilization of lithium-ion batteries.

Interfacially Induced Cascading Failure in Graphite-Silicon Composite Anodes

Silicon (Si) has been well recognized as a promising candidate to replace graphite because of its earth abundance and high-capacity storage, but its large volume changes upon lithiation/delithiation and the consequential material fracturing, loss of electrical contact, and over-consumption of the electrolyte prevent its full application. As a countermeasure for rapid capacity decay, a composite electrode of graphite and Si has been adopted by accommodating Si nanoparticles in a graphite matrix. Such an approach, which involves two materials that interact electrochemically with lithium in the electrode, necessitates an analytical methodology to determine the individual electrochemical behavior of each active material. In this work, a methodology comprising differential plots and integral calculus is established to analyze the complicated interplay among the two active batteries and investigate the failure mechanism underlying capacity fade in the blend electrode. To address performance deficiencies identified by this methodology, an aluminum alkoxide (alucone) surface-modification strategy is demonstrated to stabilize the structure and electrochemical performance of the graphite-Si composite electrode. The integrated approach established in this work is of great importance to the design and diagnostics of a multi-component composite electrode, which is expected to be high interest to other next-generation battery system.

Chemical Evolution in Silicon-Graphite Composite Anodes Investigated by Vibrational Spectroscopy

Silicon-graphite composites are under development for the next generation of high-capacity lithium-ion anodes, and vibrational spectroscopy is a powerful tool to identify the different mechanisms that contribute to performance loss. With alloy anodes, the underlying causes of cell failure are significantly different in half-cells with lithium metal counter electrodes compared to full cells with standard cathodes. However, most studies which take advantage of vibrational spectroscopy have only examined half-cells. In this work, a combination of FTIR and Raman spectroscopy describes several factors that lead to degradation in full pouch cells with LiNi_0.5Mn_0.3Co_0.2O₂ (NMC532) cathodes. The spectroscopic signatures evolve after longer term cycling compared to the initial formation cycles. Several side-reactions that consume lithium ions have clear FTIR signatures, and comparison to a library of reference compounds facilitates identification. Raman microspectroscopy combined with mapping shows that the composite anodes are not homogeneous but segregate into graphite-rich and silicon-rich phases. Lithiation does not proceed uniformly either. A basis analysis of Raman maps identifies electrochemically inactive regions of the anodes. The spectroscopic results presented here emphasize the importance of improving electrode processing and SEI stability to enable practical composite anodes with high silicon loadings.

Advances in electrode materials for Li-based rechargeable batteries

We summarize strategies to enhance the performance of electrode materials for Li-based batteries through nanoengineering and surface coating, and introduce new trends in developing alternative materials, battery concepts and cell configurations.