Li-ion cell designs, component integrity, and manufacturing processes all have critical influence on the safety of Li-ion batteries. Any internal defective features that induce a short circuit, can trigger a thermal runaway: a cascade of reactions, leading to a device fire. As consumer device manufacturers push aggressively for increased battery energy, instances of field failure are increasingly reported. Notably, Samsung made a press release in 2017 following a total product recall of their Galaxy Note 7 mobile phone, confirming speculation that the events were attributable to the battery and its mode of manufacture. Recent incidences of battery swelling on the new iPhone 8 have been reported in the media, and the techniques and lessons reported herein may have future relevance. Here we look deeper into the key components of one of these cells and confirm evidence of cracking of electrode material in tightly folded areas, combined with a delamination of surface coating on the separator, which itself is an unusually thin monolayer. We report microstructural information about the electrodes, battery welding attributes, and thermal mapping of the battery whilst operational. The findings present a deeper insight into the battery’s component microstructures than previously disseminated. This points to the most probable combination of events and highlights the impact of design features, whilst providing structural considerations most likely to have led to the reported incidences relating to this phone.

Lithium iron phosphate, LiFePO₄(LFP) has demonstrated promising performance as a cathode material in lithium ion batteries (LIBs), by overcoming the rate performance issues from limited electronic conductivity. Nano-sized vanadium-doped LFP (V-LFP) was synthesized using a continuous hydrothermal process using supercritical water as a reagent. The atomic % of dopant determined the particle shape. 5 at. % gave mixed plate and rod-like morphology, showing optimal electrochemical performance and good rate properties vs. Li. Specific capacities of >160 mAh g⁻¹were achieved. In order to increase the capacity of a full cell, V-LFP was cycled against an inexpensive micron-sized metallurgical grade Si-containing anode. This electrode was capable of reversible capacities of approximately 2000 mAh g⁻¹for over¹50 cycles vs. Li, with improved performance resulting from the incorporation of few layer graphene (FLG) to enhance conductivity, tensile behaviour and thus, the composite stability. The cathode material synthesis and electrode formulation are scalable, inexpensive and are suitable for the fabrication of larger format cells suited to grid and transport applications.

Nanostructured materials have wide potential applicability as field emitters due to their high aspect ratio. We hydrothermally synthesized MoS₂ nanoflowers on copper foil and characterized their field emission properties, by applying a tip-anode configuration in which a tungsten tip with curvature radius down to 30–100 nm has been used as the anode to measure local properties from small areas down to 1–100 µm². We demonstrate that MoS₂ nanoflowers can be competitive with other well-established field emitters. Indeed, we show that a stable field emission current can be measured with a turn-on field as low as 12 V/μm and a field enhancement factor up to 880 at 0.6 μm cathode–anode separation distance.

Fast charging promotes Li dendrite formation and its growth on graphite anodes, which affects cell performance in Li-ion batteries (LIBs). This work reports the formation of a robust SEI layer by introducing a KPF₆ inorganic additive into the electrolyte. An optimal concentration of 0.001 M KPF₆ effectively inhibits the growth of Li dendrites at 2C charging rates, compared with a commercial electrolyte. Electrolytes containing a KPF₆ additive are shown here to deliver dual effects to mitigate the growth of dendrites. A thin LiF-rich SEI layer is formed on graphite, which blocks the electron leakage pathways. Additionally, K⁺ resides at defect sites (such as particle boundaries) due to its faster diffusion rate and blocks the incoming Li⁺ and restricts the growth of Li dendrites. The electrolyte with optimum concentration of KPF₆, i.e., 0.001 M, effectively directs Li⁺ transport through the thin, durable, and low resistance LiF-rich SEI layer. This has implications for fast charging through optimization of the electrode/electrolyte interphase by controlling additive concentrations.