Mechanical reliability is a critical issue in all forms of energy conversion, storage, and harvesting. In Li-ion batteries, mechanical degradation caused by the repetitive swelling and shrinking of electrodes upon lithiation cycles is now well recognized; however, the impact of mechanical stresses on Li transport and hence the capacity of batteries is less obvious and underestimated. In particular, the stress field within the heterogeneous electrodes is complex, making the characterization of the chemomechanical behaviors of electrodes a challenging task. We develop a finite element program that computes the coupled Li diffusion and stresses in three-dimensional composite electrodes. We employ the reconstructed models of both cathode and anode materials to investigate the mechanical interactions of the constituents and their influence on the accessible capacity. The state of charge in the percolated particles is highly inhomogeneous regulated by the stress field. An ample space of design is open for the optimization of the capacity and mechanical performance of electrodes by tuning the size, shape, and pattern of active particles, as well as the properties of the inactive matrix.

Three-phase three-dimensional (3D) microstructural reconstructions of lithium-ion battery electrodes are critical input for 3D simulations of electrode lithiation/delithiation, which provide a detailed understanding of battery operation. In this report, 3D images of a LiCoO2 electrode are achieved using focused ion beam-scanning electron microscopy (FIB-SEM), with clear contrast among the three phases: LiCoO2 particles, carbonaceous phases (carbon and binder) and the electrolyte space. The good contrast was achieved by utilizing an improved FIB-SEM sample preparation method that combined infiltration of the electrolyte space with a low-viscosity silicone resin and triple ion-beam polishing. Morphological parameters quantified include phase volume fraction, surface area, feature size distribution, connectivity, and tortuosity. Electrolyte tortuosity was determined using two different geometric calculations that were in good agreement. The electrolyte tortuosity distribution versus position within the electrode was found to be highly inhomogeneous; this will lead to inhomogeneous electrode lithiation/delithiation at high C-rates that could potentially cause battery degradation.

The device developed here for XRD analysis is built on a Guinier–Lenné geometry camera. A monochromatized and focused beam goes through the plastic Li-ion cell protected by a metal–plastic laminate. Each layer of the cell produces diffracted beams that are collected by an X-ray film on the focus circle. The film is continuously moved up (1–2 mm/h) while the Li-ion cell is charged and discharged, and controlled by means of the Mac-pile system. This system allows the control of intercalation rate either in potentiostatic mode or in galvanostatic mode (Mac Pile, Bio-Logic SA, Claix, France). The crystallographic behavior of both plastic electrodes can be simultaneously and continuously observed under the real conditions of a commercial battery. LixNiO2 and C graphite as positive and negative electrodes are given as an example, respectively. Structural and chemical parameters evolving from the two electrodes can easily be correlated with the cycling curves. Studies can also be performed from room temperature up to 100 °C.

A new type of positive electrode for Li-ion batteries has been developed recently based on FeF3/C and FeF2/C nanocomposites. The microstructural and redox evolution during discharge and recharge processes was followed by electron energy loss spectroscopy (EELS) to determine the valence state of Fe by measuring the Fe L3 line energy shift and from Fe L3/L2 line intensity ratios. In addition, transition metal fluorides were found to be electron beam sensitive, and the effect of beam exposure on EELS spectra was also investigated. The EELS results indicate that for both FeF3/C and FeF2/C nanocomposite systems, a complete reduction of iron to FeO is observed upon discharge to 1.5 V with the formation of a finer FeO/LiF subnanocomposite (∼7 nm). Upon complete recharging to 4.5 V, EELS data reveal a reoxidation process to a Fe2+ state with the formation of a carbon metal fluoride nanocomposite related to the FeF2 structure.