Studies related to battery performance and long-term health of commercial Li-ion batteries (LIBs) typically have a fixed temperature parameter. However, commercial LIBs are subject to temperature fluctuations due to their local environment and operating conditions, and these transient temperatures are well known to impact long-term stability. Herein, we demonstrate the adverse effects of temperature shifts, and show that transitioning from low temperature to higher temperature can lead to catastrophic failure within practical temperature ranges experienced by commercial LIBs. We show there exists an Arrhenius relationship between the rate of acoustic attenuation and the magnitude of the temperature shift. A combination of acoustic attenuation, which marks gassing occurrence during cycling, and post mortem chemical analyses provides further mechanistic insight into the Li-rich solid electrolyte interphase (SEI) formation at low temperatures and subsequent reactions with the electrolyte at higher temperatures. Further, several strategies to prevent or mitigate catastrophic failure are introduced. On a broader scale, this research further highlights the importance of temperature and current controls integration into battery management systems (BMS) for both safety and extension of cycle life as battery systems move toward fast charge (>3 C) capability.

We have designed and tested several synthesis routes targeting a highly fluorinated disordered rocksalt (DRX) cathode, Li 1.2 Mn 0.4 Ti 0.4 O 1.6 F 0.4 , with each route rationalized by thermochemical analysis. Precursor combinations were screened to raise the F chemical potential and avoid the formation of LiF, which inhibits fluorination of the targeted DRX phase. MnF 2 was used as a reactive source of F, and Li 6 MnO 4 , LiMnO 2 , and Li 2 Mn 0.33 Ti 0.66 O 3 were tested as alternative Li sources. Each synthesis procedure was monitored using a multi-modal suite of characterization techniques including X-ray diffraction, nuclear magnetic resonance, thermogravimetric analysis, and differential scanning calorimetry. From the resulting data, we advance the understanding of oxyfluoride synthesis by outlining the key factors limiting F solubility. At low temperatures, MnF 2 consistently reacts with the Li source to form LiF as an intermediate phase, thereby trapping F in strong Li−F bonds. LiF can react with Li 2 TiO 3 to form a highly lithiated and fluorinated DRX (Li 3 TiO 3 F); however, MnO is not easily incorporated into this DRX phase. Although higher temperatures typically increase solubility, the volatility of LiF above its melting point (848 °C) inhibits fluorination of the DRX phase. Based on these findings, metastable synthesis techniques are suggested for future work on DRX fluorination.

Cation‐disordered rocksalt (DRX) cathodes have recently emerged as a promising class of cobalt‐free, high‐capacity cathodes for lithium‐ion batteries. To facilitate their commercialization, the development of scalable synthesis techniques providing control over composition and morphology is critical. To this end, a sol‐gel synthesis route to prepare Mn‐rich DRX cathodes with high capacities is presented here. Several compositions with varied Mn content and nominal F doping are successfully prepared using this technique. In‐situ X‐ray diffraction measurements demonstrate that DRX formation proceeds at moderate temperature (800 °C) through the sol‐gel route, which enables intimate mixing among reactive intermediate phases that form at lower temperatures. All synthesized compositions possess cation short‐range order, as evidenced by neutron pair distribution function and electron diffraction analysis. These DRX materials demonstrate promising electrochemical performance with reversible capacities up to 275 mAh g. Compared to the baseline oxide (Li1.2Mn0.4Ti0.4O2), the Mn‐rich compositions exhibit improved cycling stability, with some showing an increase in capacity upon cycling. Overall, this study demonstrates the feasibility of preparing high‐capacity DRX cathodes through a sol‐gel based synthesis route, which may be further optimized to provide better control over the product morphology compared to traditional synthesis methods.