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11 pages, 1504 KiB

Open AccessArticle

Nano-Alloy FeSb Wrapped in Three-Dimensional Honeycomb Carbon for High-Performance Lithium-Ion Batteries

by Nanjun Jia, Xinming Nie, Jianwei Li and Wei Qin

Batteries 2025, 11(8), 305; https://doi.org/10.3390/batteries11080305 - 8 Aug 2025

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Abstract

Sb-based anodes have great potential in lithium-ion batteries because of their relatively high theoretical capacities. However, in general, their volume changes (>150%) during charge and discharge process have a significant impact, which affects their electrochemical performances. In this paper, nano-alloy FeSb wrapped in [...] Read more.

Sb-based anodes have great potential in lithium-ion batteries because of their relatively high theoretical capacities. However, in general, their volume changes (>150%) during charge and discharge process have a significant impact, which affects their electrochemical performances. In this paper, nano-alloy FeSb wrapped in three-dimensional honeycomb graphite carbon (FeSb@C) was prepared by the freeze-drying method using sodium chloride as a template. The three-dimensional carbon can buffer the volume change in the reaction process, increasing the contact area between the electrode and electrolyte. Furthermore, the addition of metallic iron also increases the overall specific capacity and improves its electrochemical performance. As the anode of a lithium-ion battery, the optimized FeSb@C shows excellent electrochemical performance with a specific capacity of 193.0 mAh g⁻¹ at a high current density of 5 A g⁻¹, and a reversible capacity of 607.8 mAh g⁻¹ after 600 cycles of 1 A g⁻¹. It provides an effective strategy for preparing high-performance lithium-ion batteries anode materials. Full article

(This article belongs to the Special Issue Batteries: 10th Anniversary)

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16 pages, 2886 KiB

Open AccessArticle

Incremental Capacity-Based Variable Capacitor Battery Model for Effective Description of Charge and Discharge Behavior

by Ngoc-Thao Pham, Sungoh Kwon and Sung-Jin Choi

Batteries 2025, 11(8), 300; https://doi.org/10.3390/batteries11080300 - 5 Aug 2025

Viewed by 254

Abstract

Determining charge and discharge behavior is essential for optimizing charging strategies and evaluating balancing algorithms in battery energy storage systems and electric vehicles. Conventionally, a sequence of circuit simulations or tedious hardware tests is required to evaluate the performance of the balancing algorithm. [...] Read more.

Determining charge and discharge behavior is essential for optimizing charging strategies and evaluating balancing algorithms in battery energy storage systems and electric vehicles. Conventionally, a sequence of circuit simulations or tedious hardware tests is required to evaluate the performance of the balancing algorithm. To mitigate these problems, this paper proposes a variable capacitor model that can be easily built from the incremental capacity curve. This model provides a direct and insightful R-C time constant method for the charge/discharge time calculation. After validating the model accuracy by experimental results based on the cylindrical lithium-ion cell test, a switched-capacitor active balancing and a passive cell balancing circuit are implemented to further verify the effectiveness of the proposed model in calculating the cell balancing time within 2% error. Full article

(This article belongs to the Special Issue Batteries: 10th Anniversary)

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19 pages, 2626 KiB

Open AccessArticle

Process–Structure–Property Correlations in Twin-Screw Extrusion of Graphitic Negative Electrode Pastes for Lithium Ion Batteries Focusing on Kneading Concentrations

by Kristina Borzutzki, Markus Börner, Olga Fromm, Uta Rodehorst and Martin Winter

Batteries 2025, 11(8), 299; https://doi.org/10.3390/batteries11080299 - 5 Aug 2025

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Abstract

A continuous mixing process with a twin-screw extruder was investigated for graphite-based negative electrode pastes for high-power applications. In the extrusion-based mixing process, the first kneading concentration is one of the key processing parameters for systematic optimization of relevant electrode paste properties like [...] Read more.

A continuous mixing process with a twin-screw extruder was investigated for graphite-based negative electrode pastes for high-power applications. In the extrusion-based mixing process, the first kneading concentration is one of the key processing parameters for systematic optimization of relevant electrode paste properties like viscosity and particle size distribution. For different active materials at a constant electrode paste composition, a clear correlation of increasing kneading concentration with decreasing viscosity can be observed up to a certain reversal point, initiating a change in the trend and the rheological behavior, thus indicating a process limit. The fundamental effects causing this change and the associated impact on materials and battery performance were evaluated by applying further analytical methods and electrochemical characterization. It is revealed that the change in viscosity is associated with enhanced de-agglomeration of the carbon black additive and with partial particle grinding of the active material and thus a partial change in the interlayer distance of graphene layers and, correspondingly, the electrochemical behavior of the active material. Beyond this, correlations between processing parameters and product properties are presented. Furthermore, indicators are suggested with which monitoring of the machine parameters enables the detection of changes in the electrode paste characteristics. Full article

(This article belongs to the Special Issue Batteries: 10th Anniversary)

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20 pages, 2939 KiB

Open AccessArticle

Investigations of Dongyue Series Perfluorosulfonic Acid Membranes for Applications in Proton Exchange Membrane Fuel Cells (PEMFCs)

by Ge Meng, Xiang Li, Mengjie Liu, Sergey A. Grigoriev, Ivan Tolj, Jiaqi Shen, Chaonan Yue and Chuanyu Sun

Batteries 2025, 11(7), 277; https://doi.org/10.3390/batteries11070277 - 20 Jul 2025

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Abstract

This study systematically investigated the physicochemical properties and proton exchange membrane fuel cell (PEMFC) performance of perfluorosulfonic acid (PFSA) membranes with different thicknesses, which were prepared based on the resins produced by Dongyue (China) in comparison with commercial Nafion membranes. It was found [...] Read more.

This study systematically investigated the physicochemical properties and proton exchange membrane fuel cell (PEMFC) performance of perfluorosulfonic acid (PFSA) membranes with different thicknesses, which were prepared based on the resins produced by Dongyue (China) in comparison with commercial Nafion membranes. It was found that the water uptake of Dongyue membranes is significantly higher than that of Nafion, showing a significant upward trend with the thickness increase. The ion exchange capacity (IEC) of these membranes is ca. 1 mmol·g⁻¹. Moreover, the tensile strength of the Dongyue membrane was positively correlated with the thickness and was significantly higher than that of recast Nafion. Under 80 °C, all Dongyue membranes with various thicknesses (15~45 μm) exhibited PEMFC single-cell performance superior to that of Nafion. The maximum power density is observed with a thickness of 25 μm, reaching 851.76 mW·cm⁻², which is higher than that of Nafion (635.99 mW·cm⁻²). However, the oxidative stability of the prepared Dongyue PFSA series membranes exhibits a slight deficit compared to commercial Nafion membranes. Subsequently, the modification and optimization of preparation processes can be employed to improve the mechanical and chemical stability of Dongyue PFSA membranes. Full article

(This article belongs to the Special Issue Batteries: 10th Anniversary)

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21 pages, 13514 KiB

Open AccessArticle

Comparative Analysis via CFD Simulation on the Impact of Graphite Anode Morphologies on the Discharge of a Lithium-Ion Battery

by Alessio Lombardo Pontillo, Agnese Marcato, Daniele Versaci, Daniele Marchisio and Gianluca Boccardo

Batteries 2025, 11(7), 252; https://doi.org/10.3390/batteries11070252 - 2 Jul 2025

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Abstract

The morphology of electrode materials plays a crucial role in determining the performance of lithium-ion batteries. Traditional computational models often simplify graphite flakes as uniformly sized spheres, which limits their predictive accuracy. In this study, we present a computational workflow that overcomes these [...] Read more.

The morphology of electrode materials plays a crucial role in determining the performance of lithium-ion batteries. Traditional computational models often simplify graphite flakes as uniformly sized spheres, which limits their predictive accuracy. In this study, we present a computational workflow that overcomes these limitations by incorporating a more realistic representation of graphite morphologies. This workflow is designed to be flexible and reproducible, enabling efficient evaluation of electrochemical performance across diverse material structures. By exploring different graphite morphologies, our approach accelerates the optimization of material preparation techniques and processing conditions. Our findings reveal that incorporating greater morphological complexity leads to significant deviations from classical model predictions. Instead, our refined model offers a more accurate representation of battery discharge behavior, closely aligning with experimental data. This improvement underscores the importance of detailed morphological descriptions in advancing battery design and performance assessments. To promote accessibility and reproducibility, we provide the developed code for seamless integration with the COMSOL API, allowing researchers to implement and adapt it easily. This computational framework serves as a valuable tool for investigating the impact of graphite morphology on battery performance, bridging the gap between theoretical modeling and experimental validation to enhance lithium-ion battery technology. Full article

(This article belongs to the Special Issue Batteries: 10th Anniversary)

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18 pages, 1972 KiB

Open AccessArticle

Lithium Growth on Alloying Substrates and Effect on Volumetric Expansion

by Laura C. Merrill, Robert L. Craig, Damion P. Cummings and Julia I. Deitz

Batteries 2025, 11(7), 249; https://doi.org/10.3390/batteries11070249 - 29 Jun 2025

Viewed by 368

Abstract

The widespread implementation of next-generation Li metal anodes is limited, in part, due to the formation of dendritic and/or mossy electrodeposits during cycling. These morphologies can lead to battery failure due to the formation of short circuits and significant volumetric expansion at the [...] Read more.

The widespread implementation of next-generation Li metal anodes is limited, in part, due to the formation of dendritic and/or mossy electrodeposits during cycling. These morphologies can lead to battery failure due to the formation of short circuits and significant volumetric expansion at the anode. One strategy to control the electrodeposition of Li metal is to use lithiophilic materials at the anode. Here, we evaluate the impact of Ag and Au on the early stages of Li metal electrodeposition and cycling. The alloying substrates decrease the voltage for Li reduction and improve Li wetting/adhesion. We probe volumetric expansion directly through dilatometry measurements and find that the degree of volumetric expansion is less when lithium is cycled on an alloying substrate compared to a non-alloying substrate (Cu). Dilatometry experiments reveal that Au has the least amount of volumetric expansion and coin cell cycling experiments indicate that Ag yields more stable cycling compared to Au or Cu. The evaluation of in situ cross-sectional images of cycled coin cells shows that Ag has the lowest volumetric expansion in a coin cell format. Full article

(This article belongs to the Special Issue Batteries: 10th Anniversary)

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25 pages, 8273 KiB

Open AccessArticle

Laser Printing of Silicon-Containing Anodes with Polyacrylic Acid

by Ulrich Rist and Wilhelm Pfleging

Batteries 2025, 11(5), 191; https://doi.org/10.3390/batteries11050191 - 14 May 2025

Viewed by 626

Abstract

To enhance the performance of state-of-the-art lithium-ion batteries, high-capacity silicon is increasingly introduced as active material for anodes. Furthermore, advanced batteries with new electrode architectures—so-called 3D architectures—can provide significantly enhanced electrochemical performance compared to state-of-the-art batteries. To facilitate and speed up the architectural [...] Read more.

To enhance the performance of state-of-the-art lithium-ion batteries, high-capacity silicon is increasingly introduced as active material for anodes. Furthermore, advanced batteries with new electrode architectures—so-called 3D architectures—can provide significantly enhanced electrochemical performance compared to state-of-the-art batteries. To facilitate and speed up the architectural development, the laser-induced forward transfer (LIFT) process was applied as a digital additive manufacturing method. As polyvinylidene fluoride (PVDF), the binder commonly used in the LIFT process, is not a suitable binder for silicon-containing electrodes due to its weak binding forces, polyacrylic acid (PAA) was introduced as a binder for use in printable electrode pastes. Since water as a solvent in such pastes evaporates quickly and the corresponding printing time would be too short, glycerol was added to the solvent mixture in different amounts. The silicon in the printed electrodes reaches a specific capacity of more than 3000 mAh

\cdot g^{- 1}

for most of the printed anodes. To further improve the electrochemical performance of the printed electrodes, as well as the rheology of the slurries, two different conductive additives with different particle sizes were used. Full article

(This article belongs to the Special Issue Batteries: 10th Anniversary)

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Review

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117 pages, 10736 KiB

Open AccessReview

Design Principles and Engineering Strategies for Stabilizing Ni-Rich Layered Oxides in Lithium-Ion Batteries

by Alain Mauger and Christian M. Julien

Batteries 2025, 11(7), 254; https://doi.org/10.3390/batteries11070254 - 4 Jul 2025

Viewed by 1154

Abstract

Nickel-rich layered oxides such as LiNi_xMn_yCo_zO₂ (NMC), LiNi_xCo_yAl_zO₂ (NCA), and LiNi_xMn_yCo_zAl_{(1–x–y–z)}O₂ (NMCA), where x [...] Read more.

Nickel-rich layered oxides such as LiNi_xMn_yCo_zO₂ (NMC), LiNi_xCo_yAl_zO₂ (NCA), and LiNi_xMn_yCo_zAl_{(1–x–y–z)}O₂ (NMCA), where x ≥ 0.6, have emerged as key cathode materials in lithium-ion batteries due to their high operating voltage and superior energy density. These materials, characterized by low cobalt content, offer a promising path toward sustainable and cost-effective energy storage solutions. However, their electrochemical performance remains below theoretical expectations, primarily due to challenges related to structural instability, limited thermal safety, and suboptimal cycle life. Intensive research efforts have been devoted to addressing these issues, resulting in substantial performance improvements and enabling the development of next-generation lithium-ion batteries with higher nickel content and reduced cobalt dependency. In this review, we present recent advances in material design and engineering strategies to overcome the problems limiting their electrochemical performance (cation mixing, phase stability, oxygen release, microcracks during cycling). These strategies include synthesis methods to optimize the morphology (size of the particles, core–shell and gradient structures), surface modifications of the Ni-rich particles, and doping. A detailed comparison between these strategies and the synergetic effects of their combination is presented. We also highlight the synergistic role of compatible lithium salts and electrolytes in achieving state-of-the-art nickel-rich lithium-ion batteries. Full article

(This article belongs to the Special Issue Batteries: 10th Anniversary)

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