- Research Article
- 10.1149/ma2025-02542632mtgabs
Performance and Degradation Analysis of Electrode Layer: A Physics-Based Study of Particle-Binder Interactions
- Nov 24, 2025
- Electrochemical Society Meeting Abstracts
- Vinit Nagda + 2 more +2
The mechanical failure of NMC electrode materials is a critical factor governing various capacity degradation mechanisms in lithium-ion batteries. Conventional modelling, however, often neglects the complexity of electrode microstructure, limiting the accurate assessment of how mechanical failure impacts cell performance. This work presents a comprehensive electro-chemo-mechanical model, utilising tomography data to incorporate a realistic electrode microstructure including both active and inactive components. This enables a more precise characterisation of battery performance by resolving the inhomogeneous distribution of charge, stress, and mechanical damage within the electrode during cycling. These heterogeneities are then linked to experimentally observed spatial variations in degradation and uneven ageing.A key factor in mechanical failure is the volume change of active particles during lithium (de)-intercalation, which induces significant stress within the electrode material due to mechanical constraints from particle and binder connections. This mechanical damage disrupts charge transport, further increasing heterogeneity and contributing to capacity degradation. We assess and investigate the dominant mechanical degradation modes, particularly comparing particle cracking to the failure of inactive components. Specifically, we examine how mechanical damage deteriorates electronic conductivity by increasing contact resistance at various interfaces. Our findings reveal that while particle cracking increases surface area potentially aiding charge transfer, it simultaneously weakens electronic connectivity among fragmented particles, leading to higher overall electronic resistance. Crucially, the structure and distribution of carbon-binder (CBD) are shown to significantly impact both Li-ion transport efficiency and active particle utilization; its mechanical failure directly contributes to resistance build-up and effective capacity loss.
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