Architecting Three-Dimensional Lithium-Ion Battery Electrodes Using Acoustic Focusing

Abstract

Achieving high energy and power density Lithium-ion batteries (LIBs) with fast charging times is critical for enabling wide-spread adoption of electric vehicles. Conventional LIBs have planar electrodes that can be optimized for energy or power, but not both simultaneously. Three-dimensional (3D) electrodes such as those with line1,2 and grid3 patterns have demonstrated the ability to mitigate these performance trade-offs. These electrodes facilitate fast ion transport in thick electrodes, translating to faster charge times.3 However, scalable manufacturing methods for patterning 3D electrodes over large areas with small pore channels are needed. To meet this need, we leverage modeling and experiments to investigate the feasibility of using acoustic forces to fabricate line patterned electrodes. Acoustic focusing enables micron-scale control over particle placement in a fluid medium using acoustic standing waves; this has been shown to enable rapid assembly of particles, making it a promising process methodology for fabricating 3D electrodes.4 In this work, we expand a model5 that solves differential equations of acoustic forces to track particle trajectories. This model is used to capture the acoustic focusing behavior of LIB electrode materials to define how slurry viscosity, particle loading, and particle size can be modulated to achieve electrode geometries that optimize energy, power, and fast charging characteristics. Lithium Nickel Manganese Cobalt Oxide is selected as our electrode patterning material due to its relevance for electric vehicle applications. We compare our modeling results to experimental work to analyze battery material compatibility with acoustic focusing. References C. L. Cobb and S. E. Solberg, J. Electrochem. Soc., 164 (7), A1339-A1241 (2017).J. Park, S. Hyeon, S. Jeong, and H. Kim, J. Ind. Eng. Chem., 70, 178-185 (2019).K. Chen et al., J. Power Sources, 471, 228475 (2020).D. S. Melchert et al., Mater. Des., 202, 109512 (2021).R. R. Collino, T. R. Ray, L. M. Friedrich, J. D. Cornell, C. D. Meinhart and M. R. Begley, Mater. Res. Lett., 6, 191–198 (2018). Acknowledgements This material is based upon work supported by the U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy (EERE) under the Advanced Manufacturing Office (AMO) Award Number DE-EE0009112. The views expressed herein do not necessarily represent the views of the U.S. Department of Energy or the United States Government.