An in-depth historical and current review is presented on the science of lithium-ion battery (LIB) solid electrolyte interphase (SEI) formation on the graphite anode, including structure, morphology, composition, electrochemistry, and formation mechanism. During initial LIB operation, the SEI layer forms on the graphite surfaces, the most common anode material. The SEI is essential to the long-term performance of LIBs, and it also has an impact on its initial capacity loss, self-discharge characteristics, rate capability, and safety. While the presence of the anode SEI is vital, it is difficult to control its formation and growth, as they depend on several factors. These factors include the type of graphite, electrolyte composition, electrochemical conditions, and temperature. Thus, SEI formation and electrochemical stability over long-term operation should be a primary topic of future investigation in the LIB development. This article covers the progression of knowledge regarding the SEI, from its discovery in 1979 to the current state of understanding, and covers differences in the chemical and structural makeup when cell materials and components are varied. It also discusses the relationship of the SEI layer to the LIB formation step, involving both electrolyte wetting and subsequent slow charge–discharge cycles to grow the SEI

A detailed processing cost breakdown is given for lithium-ion battery (LIB) electrodes, which focuses on: 1) elimination of toxic, costly N-methylpyrrolidone (NMP) dispersion chemistry; 2) doubling the thicknesses of the anode and cathode to raise energy density; and 3) reduction of the anode electrolyte wetting and SEI-layer formation time. These processing cost reduction technologies generically adaptable to any anode or cathode cell chemistry and are being implemented at ORNL. This paper shows step by step how these cost savings can be realized in existing or new LIB manufacturing plants using a baseline case of thin (power) electrodes produced with NMP processing and a standard 10–14-day wetting and formation process. In particular, it is shown that aqueous electrode processing can cut the electrode processing cost and energy consumption by an order of magnitude. Doubling the thickness of the electrodes allows for using half of the inactive current collectors and separators, contributing even further to the processing cost savings. Finally wetting and SEI-layer formation cost savings are discussed in the context of a protocol with significantly reduced time. These three benefits collectively offer the possibility of reducing LIB pack cost from $502.8 kW h−1-usable to $370.3 kW h−1-usable, a savings of $132.5/kWh (or 26.4%)