Guide to Lithium-ion Battery Solutions

Importance of the Topic

Lithium-ion batteries power a wide range of devices from portable electronics to electric vehicles. Consistent performance, safety and longevity of these cells depend on the mechanical, thermal and chemical stability of each component. Advanced analytical methods play a key role in characterizing electrode materials, separators, electrolytes and cell internals to optimize manufacturing processes, ensure quality control and predict degradation under real-world conditions.

Objectives and Overview

This guide presents a comprehensive evaluation strategy for lithium-ion battery materials using a suite of analytical instruments. It covers:

• Mechanical testing of electrodes and separators (compression, tensile, puncture)
• Thermal analysis (DSC, TGA, TMA)
• Organic and inorganic component characterization (FTIR, ion chromatography, GC-MS)
• Non-destructive internal imaging (X-ray CT)
• Microanalysis (EPMA, scanning probe microscopy)
• Particle size and morphology assessment (laser diffraction, dynamic image analysis)

The aim is to demonstrate how each technique can reveal material properties, detect defects and inform design improvements.

Methodology and Used Instrumentation

Mechanical strength and deformation were measured with the Micro Compression Tester (MCT) and the AUTOGRAPH AGX-V universal tester, including digital image correlation for strain mapping. Thermal transitions and stability were probed by DSC-60 Plus, TGA-50 and TMA-60 analyzers. Electrolyte and separator chemistry was characterized under inert atmosphere using the IRSpirit FTIR system and by ion chromatography (HIC-ESP) and GC-MS (QP2020 NX) for solvent and additive profiling. Internal gas species were detected by GC-BID (Nexis GC-2030). Non-destructive internal structures and electrode deformation were imaged with inspection-grade microfocus X-ray CT (inspeXio SMX-225CT). Elemental distribution and chemical bonding at micrometer scale were obtained with EPMA-8050G. Surface topography and nanoscale conductivity mapping used SPM-Nanoa cantilever probe microscopy. Particle size distributions and aggregation states were assessed by SALD-2300 laser diffraction and DIA-10 dynamic image analysis.

Main Results and Discussion

Compression tests revealed orders-of-magnitude differences in fracture strength between LiCoO2 and LiMn2O4 particles, guiding electrolyte molding conditions. Separator tensile and puncture tests at 25 °C to 90 °C showed enhanced elongation at elevated temperature with preserved strength up to 60 °C. DSC identified separator melting transitions near 100–140 °C, critical for thermal shutdown design. TGA quantified moisture uptake in electrode materials at trace levels. FTIR comparison under argon and air confirmed solvation peaks of LiPF6 in carbonate solvents and highlighted water-induced OH absorptions in air. Chromatographic analyses detected degradation products of LiPF6 and trace additives, while GC-BID profiles correlated gas evolution with cell aging. X-ray CT provided non-destructive visualization of electrode deformation through charge/discharge cycles and post-explosion damage. EPMA mapping and SPM conductivity imaging linked elemental distribution and conductive pathways. Particle sizing and image analysis identified fine aggregation in carbon blacks and coarse contaminants in electrode powders that can impair battery performance.

Benefits and Practical Applications

• Comprehensive materials screening to improve electrode formulations and separator safety features
• In-process quality control for moisture content, particle dispersion and coating uniformity
• Early detection of aging mechanisms through gas analysis and CT imaging
• Microstructural insights that guide binder selection and conductive additive optimization
• Non-destructive methods that reduce sample count and track degradation over time

Future Trends and Opportunities

Integration of multimodal analytics with machine learning promises accelerated correlation of test data to cell performance. In situ and operando adaptations of thermal, spectroscopic and imaging methods will deepen understanding of dynamic processes during cycling. Miniaturized and high-throughput versions of key instruments will enable rapid screening of novel electrode chemistries and solid electrolytes. Improved detectors and data processing will extend detection limits for impurities and early-stage degradation products.

Conclusion

A strategic combination of mechanical, thermal, chemical and imaging techniques provides a robust framework for lithium-ion battery development and quality assurance. By correlating material properties with cell behavior, these methods support safer, longer-lasting and higher-performance batteries.

References

No formal references were provided within the source document.