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Unveiling the impact of electrolyte deficiency on uneven lithium plating in lithium-ion batteries: Integrating modeling and experimental validation

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  • Chen, Fei
  • Wu, Zhenxuan
  • Chen, Tianxin
  • Lu, Kunjie
  • Hua, Jianfeng
  • Han, Xuebin
  • Ouyang, Minggao
  • Zheng, Yuejiu

Abstract

Lithium-ion batteries are widely adopted across industries for their high energy density and efficiency. However, they encounter significant challenges related to safety and longevity. A critical issue is lithium plating, which leads to rapid capacity degradation and potential thermal incidents. While current research primarily addresses lithium plating from design and operational perspectives, studies on manufacturing defects contributing to these issues remain limited. This study simulated electrolyte under-infiltration defects by artificially reducing the electrolyte volume injected during production. Utilizing a Newman model, side reactions such as lithium intercalation, plating, and stripping on the anode are simulated. Experimental validation quantifies how these defects affect battery performance. These finding reveal that electrolyte under-infiltration causes uneven distribution of lithium plating, particularly in regions with restricted lithium ion transport. This non-uniform distribution exacerbates the risk of lithium plating-related issues. This research enhances understanding of manufacturing defect mechanisms in lithium-ion batteries and offers theoretical insights to improve battery manufacturing quality. Addressing these issues aims to enhance battery safety and prolong lifespan, benefiting applications reliant on lithium-ion technology.

Suggested Citation

  • Chen, Fei & Wu, Zhenxuan & Chen, Tianxin & Lu, Kunjie & Hua, Jianfeng & Han, Xuebin & Ouyang, Minggao & Zheng, Yuejiu, 2025. "Unveiling the impact of electrolyte deficiency on uneven lithium plating in lithium-ion batteries: Integrating modeling and experimental validation," Energy, Elsevier, vol. 322(C).
    • Handle: RePEc:eee:energy:v:322:y:2025:i:c:s0360544225011065
    DOI: 10.1016/j.energy.2025.135464
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    References listed on IDEAS

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    1. David, Lamuel & Ruther, Rose E. & Mohanty, Debasish & Meyer, Harry M. & Sheng, Yangping & Kalnaus, Sergiy & Daniel, Claus & Wood, David L., 2018. "Identifying degradation mechanisms in lithium-ion batteries with coating defects at the cathode," Applied Energy, Elsevier, vol. 231(C), pages 446-455.
    2. Fei Chen & Wenkuan Zhu & Xiangdong Kong & Yunfeng Huang & Yu Wang & Yuejiu Zheng & Dongsheng Ren, 2022. "Study on the Homogeneity of Large-Size Blade Lithium-Ion Batteries Based on Thermoelectric Coupling Model Simulation," Energies, MDPI, vol. 15(24), pages 1-19, December.
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