The impacts on battery cell ageing from high current operation are investigated using commercial cells. This study utilised two tests–(i) to establish the maximum current limits before cell failure and (ii) applying this maximum current until cell failure. Testing was performed to determine how far cycling parameters could progress beyond the manufacturer’s recommendations. Current fluxes were increased up to 100 C cycling conditions without the cell undergoing catastrophic failure. Charge and discharge current capabilities were possible at magnitudes of 1.38 and 4.4 times, respectively, more than that specified by the manufacturer’s claims. The increased current was used for longer term cycling tests to 500 cycles and the resulting capacity loss and resistance increase was dominated by thermal fatigue of the electrodes. This work shows that there is a discrepancy between manufacturer-stated current limits and actual current limits of the cell, before the cell undergoes catastrophic failure. This presumably is based on manufacturer-defined performance and lifetime criteria, as well as prioritised safety factors. For certain applications, e.g., where high performance is needed, this gap may not be suitable; this paper shows how this gap could be narrowed for these applications using the testing described herein.

The ubiquitous deployment of Li-ion batteries (LIBs) in more demanding applications has reinforced the need to understand the root causes of thermal runaway. Herein, we perform a forensic simulation of a real-case failure scenario, using localised heating of Li(Ni_0.5Mn_0.3Co_0.2)O₂ versus graphite 18650 cylindrical cells. This study determined the localised temperatures that would lead to venting and thermal runaway of these cells, as well as correlating the gases produced as a function of the degradation pathway. Catastrophic failure, involving melting (with internal cell temperatures exceeding 1085 °C), deformation and ejection of the cell componentry, was induced by locally applying 200 °C and 250 °C to a fully charged cell. Conversely, catastrophic failure was not observed when the same temperatures were applied to the cells at a lower state of charge (SOC). This work highlights the importance of SOC, chemistry and heat in driving the thermal failure mode of Ni-rich LIB cells, allowing for a better understanding of battery safety and the associated design improvements.

Without suitable design, lithium ion cells within electronic devices can be exposed to localised heating causing a thermal runaway event. This study focussed on determining the localised temperatures that would lead to venting and thermal runaway of a cell as well as to monitor the gases exhumed by these events. Commercially available 18650 cylindrical cells were monitored while being exposed to localised temperatures up to 250 °C. These temperatures were then applied while the cell was charged to simulate a heating scenario by the device electronics. The resulting damage to the cell was evaluated using x-ray tomography, mechanical testing and microscopy. Gases were analysed using a mass spectrometer. This work elucidates a particular failure mode of lithium ion cells allowing for a better understanding of battery safety and associated system design improvements. Additionally we anticipate this approach to facilitate further regulatory approvals for consumer electronics.

The lithium-ion cylindrical cell is designed as a thin-walled pressure vessel, with various engineering controls to mitigate catastrophic failure. With an increase in pressure inside the cell, given suitable can wall thickness, the cell will fail through the header componentry. A tear down and inspection method has been developed to observe the header design and componentry of cells. A range of cylindrical cells were investigated - from 18650 to 46950 in size. This involved visual inspection, x-ray tomography, chemical analysis and microscopy. The presence of safety componentry, thickness and material type is discussed; factors which affect the propensity of the cell to fail at this location. Commonly observed was the Current Interrupt Device (CID) vent disc which is designed to mechanically deform in response to pressure increase within the cell. This in turn disconnects the cell circuitry and ruptures, initiating the venting process. Furthermore, cells typically contained a Positive Temperature Coefficient (PTC) device which protects the battery from external short circuits and electrical abuse conditions by limiting current flow when the cell reaches a particular temperature. This approach clearly outlines the safety componentry and their respective functions used within these cell sizes, allowing for a better understanding of battery safety. Additionally, we expect this work to disseminate new developments in larger format lithium-ion batteries as they are being sought for better system performance.

The mass production of lithium-ion cells involves applying a range of manufacturing processes to a range of materials. These processes inevitably result in residual stresses within the individual materials, which when abetted by operational stresses can cause deformation and fracture of the componentry. This contributes to the degradation of electrochemical properties, device performance, and durability of the cells; leading ultimately to cell failure. This experimental study is concerned with determining the mechanical degradation of componentry within cylindrical cells. Mechanical degradation was evaluated for commercial cells using x-ray tomography, mechanical testing and microscopy. Nanoindentation testing was used to characterise mechanical changes in the foil material in three conditions: before cell manufacture, after cell manufacture and after aging. This work represents a novel ex situ characterisation tool and a new approach to understanding degradation in electrochemical systems. Additionally, we anticipate this work to aide modelling of and controlling degradation within electrochemical systems.