Introduction to Battery architecture

Lecture 2

Taylor Brandt, Mengjie Yu, Richard M. Laine, Eleni Temeche, Xinyu Zhang,

Depts of Materials Sci. & Eng. And Macromolecular Sci. & Eng.

University of Michigan
Content

 Battery Architecture
 Cell formats

 Components in:
 Coin cell
 Prismatic cell
 Pouch cell

 Solid state battery assembly

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 Cell formats

 Cylindrical cells
 Prismatic cells
 Pouch cells
 Coin cells

https://learn.sparkfun.com/tutorials/what-is-a-battery/all
 Cylindrical Cells—Jelly Roll
 Definition
 Cell with positive, negative electrodes, and separator
in cylindrical container

C. J. Cleveland et al., Dictionary of Energy, Second Edition; M Zschornak et al.,

Physical Sciences Reviews, 2018, 20170111; http://nbobattery.com/product/html/?18.html
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 Cylindrical Cells

 Advantages:
 Good mechanical stability
 High energy density
 Lowest cost to manufacture
 Mass produced in standard sizes
 E.g. 18650 cell: 18 mm dia., 65 mm long
 AAA battery single cell 10.5 mm in dia. and 44.5 mm long

 Challenges:
 Low packaging efficiency
 Relative heavy packing material

 Applications:
Different cylindrical cell models
 Traditional: power tools, medical instruments
 New demands: military, drones and electric car

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http://nbobattery.com/product/html/?18.html
AAA vs 18650
 Cell formats prismatic cells
 Definition
 Cell where positive, negative plates, and separator,
stacking in prismatic container

9 V Prismatic, Rechargeable
Built-in USB
Lithium Polymer

w/USB Cable

C. J. Cleveland et al., Dictionary of Energy, Second Edition; M Zschornak et al., Physical Sciences Reviews, 2018, 20170111 7
https://www.vpwllc.com/prismatic-cells/
 Prismatic Cells

 Advantages:
 Hard case provides protection
 No standard size – advantage in design
 Customizable packaging to meet cell/pack requirements

 Challenges:
 No standard size – disadvantage in production
 Harder/more expensive to manufacture
 Larger cells difficult to automate assembly
 Often ineffective in high pressure situations

 Applications:
 Mobile phones, tablets and laptops

M Zschornak et al., Physical Sciences Reviews, 2018, 20170111; 8

https://www.vpwllc.com/prismatic-cells/
 Coin Cells

 Definition
 Miniature battery w/circular cross-section
 Overall height < diameter

 Typical format for testing materials

C. J. Cleveland et al., Dictionary of Energy, Second Edition; 9

E Talaie et al., Chem. Mater., 2017, 29, 1, 90-105
 Coin Cells

 Advantages:
 Easy & cheap to manufacture
 Standardized sizes

 Challenges:
 Usually single layer – limited capacity
 Often require slow charge rates
 Performance not scalable

 Applications:
 Portable: cordless telephones, medical devices

E Talaie et al., Chem. Mater., 2017, 29, 1, 90-105 10

https://en.wikipedia.org/wiki/Button_cell
 Coin cells--utility for research

 Symmetric cell
 Uses 2 identical electrodes
Symmetric cell Half cell
 One lithiated, the other delithiated
 Limits Li supply and Li foil reactions w/electrolytes
 Differs from full cell
 Only side reactions induced by the range of tested
electrode’s potential can be observed
Working electrode
 Half cell
 Using Li foil as reference/counter electrode
 Easy to make, can provide repeatable data
 Abundance of Li Working electrode

 Unable to observe problems with Li consumption

J. C. Burns et al., J. Electrochem. Soc., 2011, 158 (12) A1417-A1422; 11

T. Matsuyama et al., J. Electrochem. Soc., 2019, 166 (2) A329-A333
 Pouch Cells
 Definition
 Prismatic cell with metallic case replaced with
 flexible, heat-sealable foil package

C. J. Cleveland et al., Dictionary of Energy, Second Edition; 12

M Zschornak et al., Physical Sciences Reviews, 2018, 20170111
 Pouch Cells
 Advantages:
 Lightweight packaging
 Optimized packing efficiency >95%
 Easily stackable

 Challenges:
 No inherent protection against swelling
 High temperature and humidity shorten cell life
 Robust cell packaging required at pack level
 Electrode delamination
 Works best with pressure on stack

Swollen pouch cell

https://www.vpwllc.com/pouch-cells/ 13
https://www.stockwell.com/blog/designing-battery-pad-for-li-ion-pouch/
 Pouch Cells
Pouch cells
 Commercial battery packs stacking
&
joining

 Applications:
 Electric bikes, scooters Modules
stacking
 Consumer electronics
&
 Electric tools connecting

http://www.talgaresources.com/IRM/content/default.aspx 14
https://battery-system.com/product/3-7v-lipo-battery-pack-pouch-cell
 Pouch vs coin cells--utility for research
 Pouch cells:
 High areal capacity cathode (3.8 mAh cm−2) Pouch cell
 Limited Li (N:P ratio of 2.6)
 Areal reversible capacity of anode to cathode (positive)
 Lean electrolyte (E/C ratio of 3.0 g Ah−1)
 E/C ratio: electrolyte mass to capacity
 Commercial Li+ batteries: N/P ~1.1, E/C ~1.3 g Ah−1
Coin cell
 Typical Li metal coin cells (half cell):
 Low areal capacity cathode (~1.0 mAh cm−2)
 large excess Li (N:P ratio of 50)
 Flooded electrolyte (E/C ratio >75 g Ah−1)
 Results inconsistent with practical batteries

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C. J. Niu et al., Nature Energy, 2019, 4, 551–559
 Pouch cell processing Z-stacking
 Z-stacking is more commonly used in industry

Regular stacking: Z-stacking: Z-stacking:

Stacked electrodes Stacked electrodes Z-folded electrodes
& & &
stacked separators Z-folded separators Z-folded separators
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A. Rheinfeld et al., J. Electrochem. Soc., 2020, 167, 013511; J. Schmitt et al., CIRP Ann-Manuf. Tech., 2014, 63, 9–12
 Pouch cell processing regular-stacking

Tab is Cu, Ni added by

welding all electrodes
at one time

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M. S. K. Mutyala et al., J. Powder Sources, 2014, 260 43–49
Conducting tabs added

PP sealant
 Pouch cell processing electrode-to-tab joining
 Tab/terminal:
 Cathode: Al
 Anode: Ni or Cu

 Sealant:
 Usually contains PP
 Bond with cell case (Al laminated film) under heating

 Electrode-to-tab weld:
 Gather all the current collectors inside a cell
 Join all current collectors to a tab which exits casing
 Allow energy to be transferred to external sources

http://www.soteriabig.com
https://www.targray.com/li-ion-battery/packaging-materials/tabs 19
http://www.aga88.com/products-services/ultrasonic-welding/applications/batteries/
 Electrode-to-tab joining welding
 Commonly used welding methods
 Ultrasonic friction welding (UMW)
 Join substrate materials by high frequency ultrasonic vibration (>20 kHz) under a clamping pressure
 Resistance spot welding (RSW)
 Metal sheets welded together by electrical current and pressure between two electrodes
 Laser Beam Welding (LBW)
 Materials fused together by concentrated heat generated by a laser beam

Working
principles of
← UMW
RSW →

J. Coignard et al., World Electr. Veh. J. 2018, 9(2), 22 20

https://www.telsonic.com/en/metal-welding/battery-foil-sheet-cylinder-welding/; https://www.teknat.uu.se/student
Electrode-to-tab joining/welding
 Pouch cell case Al laminated film

Punch Assembly

Nylon

Al Adhesives

Polypropylene

https://www.tvservice.basf.com/portal/basf/en/dt.jsp?setCursor=1_203919_492322&cursorPath=%7C492298%7C481768%7C492296%7C492298&setClientType=Desktop
https://www.mtixtl.com/AluminumLaminatedFilm400mmWx7.5mL-EQ-alf-400-7.5M.aspx 22
https://www.tmaxcn.com/aluminum-laminated-film-pouch-cell-case-cup-punching-forming-machine-with-optional-die_p910.html
 Pouch cell case Al laminated film
 Nylon:
Nylon
 Keeps the shape of aluminum laminated film
 Avoids deformation before manufacture Al Adhesives

 Aluminum: Polypropylene
 A layer of metal Al
 Al reacts with oxygen to form a dense oxide film that prevents water and gas from penetrating
 Blocks moisture infiltration (Nylon not waterproof)
 Provides the plasticity for punching

 Polypropylene:
 Heating PP layer causes melting/bonding to seal cells
 Melting temperature ~ 100°C and PP is viscous

 Thickness: 71 - 156 μm
 Different thickness for each layer in different models
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https://www.targray.com/li-ion-battery/packaging-materials/aluminum-laminate-pouch
 Seal--temporary seal
 Temporary seal:
 Cell is completely sealed with an air receiver/air bag
 Electrolyte wets/saturates electrodes

 Formation:
 Cyclic charge/discharge, form SEI-under pressure forcing
gases into receiver bag
 Air receiver collects produced gas

Air receiver
← Formation towers
https://www.mtixtl.com/8mmWidthNickelTabasNegativeTerminalforPolymerLi-ionBattery50pcs.aspx 24
http://www.youfil.com/lead-acid-storage-battery-production-equipment/Battery-formation-line.html
 Seal--final seal
 Warm-pressing:
 Improve uniformity of cell flatness and thickness
Cut at final seal
 Drive air out into receiver
 Closely press separators and electrodes together
 Shorten Li+ diffusion distance to reduce internal resistance

 Final seal:
 Degas
 Air receiver punctured 1st under vacuum to remove
residual gases
 Cell vacuum-seal
 An important step
 Remove air receiver
 Last step in assembly
Air receiver
 Preferably limit time between formation and degassing
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https://www.mtixtl.com/8mmWidthNickelTabasNegativeTerminalforPolymerLi-ionBattery50pcs.aspx
 Challenges of Li+ battery architecture

 Volume changes & structural degradation due to Li insertion/deinsertion

 Liquid electrolyte leakage
 Current collector corrosion
 High peripheral mass & housing package size
Decreases the energy density

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 Development of solid-state batteries (SSBs) could overcome these challenges
 SSB architectures

Solid state electrolyte

27
Kerman, Kian, et al. Journal of The Electrochemical Society 164.7 (2017): A1731.
 Anode free-SSBs

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Kerman, Kian, et al. Journal of The Electrochemical Society 164.7 (2017): A1731.
Porous separator vs. solid electrolyte separators

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 2-D battery configuration
 2D battery design compromise between energy density and power density because
of the limitation in footprint area.
 Limited areal capacity 0.5 – 5 mAhcm-2
 Making electrodes thicker in order to store more energy is not a viable approach
 The mechanical integrity of the film decreases due to expansion and contraction
of the active materials during cycling
 Thicker films reduce the power density of the device

MCMB, mesocarbon microbead

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Arthur, Timothy S., et al. "Three-dimensional electrodes and battery architectures," MRS Bulletin 2011 36, 523-531.
 3-D battery configuration
 3D battery architectures takes advantage of the third dimension, height,
 The amount of electrode material within a given footprint area is high
 Areal capacity ~ 10 mAhcm-2
 Energy density and power density are effectively decoupled
 Anode and cathode arrangements are unaffected by the additional thickness

31
Arthur, Timothy S., et al. "Three-dimensional electrodes and battery architectures." MRS Bulletin 2011 36, 523-531.
 SSBs-micro batteries
3D micro batteries for MEMS devices
• Powering autonomous systems for applications e.g. medical implants, communications, & sensing
• 3D micro batteries use nanostructures to increase areal capacity; high surface area enables fast
charge/discharge
• Thin films deposited in trenches, pores, nanowires, or other structures to increase effective area
within the same footprint.

32
Arthur, Timothy S., et al. "Three-dimensional electrodes and battery architectures." MRS Bulletin 2011 36, 523-531.
 Examples of 3-D battery configuration

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Arthur, Timothy S., et al. "Three-dimensional electrodes and battery architectures." MRS Bulletin 2011 36, 523-531.
 Geometries to overcome material limitations
 Material properties at nanoscale can differ from bulk properties
 Nano and microscale geometries can result in different apparent properties

 Significantly higher surface to volume ratio - fast charge/discharge

In situ TEM
tensile testing
of Si nanowires

Measured ultimate tensile strength vs Si NW dia.,

revealing increasing strength with decreasing
diameter 34
D-M. Tang et al. "Mechanical properties of Si nanowires as revealed by in situ TEM & molecular dynamics simulations." Nano let. 2012 12, 1898-1904.
 Si Nanowire Anodes

• Si volume changes drastically (400%) during Li

insertion and removal
• structural damage
• Loss of electronic contact
• Nanowire morphology:
• Leaves open space for expansion
• Size dependent material properties
• Direct electrical contact with current collector

35
Arthur, Timothy S., et al. "Three-dimensional electrodes and battery architectures." MRS Bulletin 2011 36, 523-531.
 Li plating: Textures Li Surface

•Mechanically stamped Li electrode

• Li plates in pits (where there is higher current density)
•Suppresses uncontrolled Li dendrite growth

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 Nano - Cu current collectors

 Inhomogeneities occur plating Li onto planar current collectors

 Nucleation creates hotspots that grow into dendrites
• Microporous Cu current collectors
• More uniform current density
• Higher surface area - lower local current
density
• Li fills in the pores and dendrites are
suppressed
• Scale and pore size matters
• < 5 um pores perform significantly better
than ~170 um pores

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 Challenges for implementing 3D geometries

• SEI formation on high surface areas can be particularly detrimental

• SSBs require thin, conformal, pinhole free films
• Continued development of solid-state electrolytes
• In many cases, nano & micro-structures slow and costly to produce
• Production scalability
• Competitive market pricing
• Many approaches require further rigorous testing under a variety of conditions
• Depth of charge/discharge
• Rate of charge/discharge
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