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Li-ion batteries contain excess anode area to improve manufacturability and prevent Li plating. These overhang areas in graphite electrodes are active but experience decreased Li+ flux during cycling. Over time, the overhang and the anode portions directly opposite to the cathode can exchange Li+, driven by differences in local electrical potential across the electrode, which artificially inflates or decreases the measured cell capacity. Here, we show that lithiation of the overhang is less likely to happen in silicon anodes paired with layered oxide cathodes. The large voltage hysteresis of silicon creates a lower driving force for Li+ exchange as lithium ions transit into the overhang, rendering this exchange highly inefficient. For crystalline Si particles, Li+ storage at the overhang is prohibitive, because the low potential required for the initial lithiation can act as thermodynamic barrier for this exchange. We use micro-Raman spectroscopy to demonstrate that crystalline Si particles at the overhang are never lithiated even after cell storage at 45 oC for four months. Since the anode overhang can affect the forecasting of cell life, cells using silicon anodes may require different methodologies for life estimation compared to those used for traditional graphite-based Li-ion batteries.

Development of new polymeric binders can help enable the use of silicon-rich anodes in Li-ion batteries, by providing stronger adhesion to the active material particles. The compositional features that improve interfacial interactions and mechanical properties can often impart electronic conductivity and redox activity to these polymers, which are generally seen as beneficial to cell performance. Alternatively, it is also possible that the addition of charge-transferring centers to the electrode can accelerate cell degradation. Here, we use an aromatic polyimide (~320 mAh/g of reversible capacity) to explore how a redox-active conductive polymer can affect cell performance. We demonstrate that the lithiated polymer is less stable than the traditional binders upon storage, leading to increased rates of calendar aging. Furthermore, we show that the adhesion properties of the polymer deteriorate upon repeated cycling, to an extent that is proportional to the degree of delithiation of the binder. More critically, we show that progressive degradation of the redox behavior of the polymer leads to the release of extra Li+ into the cell, which can give the false perception of good performance even under conditions of poor stability. Our work suggests that redox-active conductive binders can sometimes be detrimental to cell performance, and that works evaluating new polymers must include careful experimental validation under realistic conditions.

It is generally believed that silicon-based anodes for Li-ion batteries would benefit from stronger binders, as cyclic volume changes would not disrupt the cohesion of the composite electrode. Here, we put this belief to the proof by testing electrodes containing SiOx particles and an aromatic polyimide binder. We observe that the electrodes can stretch laterally by as much as 6% during the first cycle, indicating that internal stresses are high enough to induce plastic deformation on the copper current collector. Remarkably, no coating delamination is observed. Additional consequences were size-dependent: while pouch-cell-sized electrodes developed wrinkles, coin-cell-sized ones remained mostly smooth. We demonstrate that wrinkling of the current collector damages the electrode coating, inactivating SiOx domains and accelerating capacity fade. This size-dependent performance decay indicates that, in extreme cases, testing outcomes are highly dependent on scale. Novel battery materials may require testing at larger cell formats for complete validation.

Small amounts of high-capacity silicon-based materials are already used in the anode of commercial Li-ion batteries, helping increase their energy density. Despite their remarkable storage capability, silicon continuously reacts with the electrolyte, accelerating time-dependent cell performance fade. Nevertheless, very limited information is available on the specific consequences of this reactivity for the calendar aging of Li-ion cells. Here, we analyze aging effects on 450 mAh pouch cells containing 15 wt% of Si (and 73 wt% graphite) after storage at 21 oC for four years. We show that severe losses of Si capacity occurred due to particle isolation when cells were stored at high states of charge (SOC), but not when cells were fully discharged prior to storage. Impedance rise was also significantly higher when cells were kept at high SOCs and was mostly due to phenomena taking place at the cathode; the continuous electrolyte reduction at the anode did not lead to a major increase in bulk electrode resistance. A series of post-test characterization provided additional information on the effects of time and SOC on the calendar aging of Si-containing cells. Our study highlights the many challenges posed by Si during calendar aging and can inform future studies in the field.

Li-ion battery (LIB) research has continuing importance for the entire range of applications from consumer products to vehicle electrification and grid stabilization. In many cases, standard electrochemical methods only provide an overall voltage or specific capacity, giving an inadequate description of parallel redox processes or chemical gradients at the particle and pack level. X-ray absorption fine structure (XAFS) is frequently used to augment bulk electrochemical data, as it provides element-specific changes in oxidation state and local atomic structure. Such microscopic descriptors are crucial for elucidating charge transfer and structural changes associated with bonding or site mixing, two key factors in evaluating state of charge and modes of cell failure. However, the impact of XAFS on LIB research has been significantly constrained by a logistical barrier: contemporary XAFS work is performed almost exclusively at synchrotron x-ray light sources, where beamtime is infrequent and experiment time-frames are limited. Here we show that modern laboratory based XAFS can not only be applied to, e.g., characterization of ex situ LIB electrode materials, but can also be used for operando studies at industrially-relevant charging rates in a standard pouch cell preparation. Such capability enables accelerated discovery of new materials and improved operation modes for LIBs.