Reducing cost and increasing energy density are two barriers for widespread application of lithium-ion batteries in electric vehicles. Although the cost of electric vehicle batteries has been reduced by $70% from 2008 to 2015, the current battery pack cost ($268/kWh in 2015) is still >2 times what the USABC targets ($125/kWh). Even though many advancements in cell chemistry have been realized since the lithium-ion battery was first commercialized in 1991, few major breakthroughs have occurred in the past decade. Therefore, future cost reduction will rely on cell manufacturing and broader market acceptance. This article discusses three major aspects for cost reduction: (1) quality control to minimize scrap rate in cell manufacturing; (2) novel electrode processing and engineering to reduce processing cost and increase energy density and throughputs; and (3) material development and optimization for lithium-ion batteries with high-energy density. Insights on increasing energy and power densities of lithium-ion batteries are also addressed.

To correlate the carbon properties, e.g. surface area and porous structure, with the electrochemical behaviors of carbon/sulfur (C/S) composite cathodes for lithium-sulfur (Li-S) batteries, four different carbon frameworks including Ketjen Black (KB, high surface area and porous), Graphene (high surface area and nonporous), Acetylene Black (AB, low surface area and nonporous) and Hollow Carbon Nano Sphere (HCNS, low surface area and porous) are employed to immobilize sulfur (80 wt%). It has been revealed that high surface area of carbon improves the utilization rate of active sulfur and decreases the real current density during the electrochemical reactions. Accordingly, increased reversible capacities and reduced polarization are observed for high surface area carbon hosts such as KB/S and graphene/S composites. The porous structure of KB or HCNS matrix promotes the long-term cycling stability of C/S composites but only at relatively low rate (0.2 C). Once the current density increases, the pore effect completely disappears and all Li-S batteries show similar trend of capacity degradation regardless of the different carbon hosts used in the cathodes. The reason has been assigned to the formation of reduced amount of irreversible Li2S on the cathode as well as shortened time for polysulfides to transport toward lithium anode at elevated current densities. This work provides valuable information for predictive selection on carbon materials to construct C/S composite for practical applications from the electrochemical point of view.

No abstract

Silicon-graphite composites are under development for the next generation of high-capacity lithium-ion anodes, and vibrational spectroscopy is a powerful tool to identify the different mechanisms that contribute to performance loss. With alloy anodes, the underlying causes of cell failure are significantly different in half-cells with lithium metal counter electrodes compared to full cells with standard cathodes. However, most studies which take advantage of vibrational spectroscopy have only examined half-cells. In this work, a combination of FTIR and Raman spectroscopy describes several factors that lead to degradation in full pouch cells with LiNiMnCoO (NMC532) cathodes. The spectroscopic signatures evolve after longer term cycling compared to the initial formation cycles. Several side-reactions that consume lithium ions have clear FTIR signatures, and comparison to a library of reference compounds facilitates identification. Raman microspectroscopy combined with mapping shows that the composite anodes are not homogeneous but segregate into graphite-rich and silicon-rich phases. Lithiation does not proceed uniformly either. A basis analysis of Raman maps identifies electrochemically inactive regions of the anodes. The spectroscopic results presented here emphasize the importance of improving electrode processing and SEI stability to enable practical composite anodes with high silicon loadings.