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<p>While electrochemical degradation mechanisms in lithium-ion batteries are well studied, the influence of mechanical factors remains poorly understood. Here we introduce a high-precision stack-pressure control and dilatometry tool to apply a uniform and constant stack pressure on electrodes independent of electrode swelling. By increasing stack pressure fourfold over typical initial values, we double the lifetime of graphite ‖ LiNi<sub>0.8</sub>Mn<sub>0.1</sub>Co<sub>0.1</sub>O<sub>2</sub> cells, an industrially relevant battery chemistry, without altering active materials or electrolytes. This suggests that many lithium-ion batteries operate under sub-optimal stack-pressure conditions, leading to curtailed lifetimes. We demonstrate that different degradation mechanisms emerge outside the optimal pressure window: low stack pressure accelerates cathode cracking, whereas high pressure promotes lithium plating. Our findings highlight coupled mechanical–electrochemical degradation mechanisms and identify stack-pressure optimization as a practical solution for increasing cycling stability.</p>

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The interplay between stack pressure, mechanical expansion and degradation pathways in lithium-ion batteries

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年6月29日

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  • Heng Wang,
  • Rui Wang,
  • Christopher A. O’Keefe,
  • Erik Björklund,
  • Daniela Proprentner,
  • Joe C. Stallard,
  • Hwee Jien Tan,
  • Wesley M. Dose,
  • Louis F. J. Piper,
  • Robert S. Weatherup,
  • Angkur J. D. Shaikeea,
  • Clare P. Grey,
  • Michael De Volder

摘要

While electrochemical degradation mechanisms in lithium-ion batteries are well studied, the influence of mechanical factors remains poorly understood. Here we introduce a high-precision stack-pressure control and dilatometry tool to apply a uniform and constant stack pressure on electrodes independent of electrode swelling. By increasing stack pressure fourfold over typical initial values, we double the lifetime of graphite ‖ LiNi0.8Mn0.1Co0.1O2 cells, an industrially relevant battery chemistry, without altering active materials or electrolytes. This suggests that many lithium-ion batteries operate under sub-optimal stack-pressure conditions, leading to curtailed lifetimes. We demonstrate that different degradation mechanisms emerge outside the optimal pressure window: low stack pressure accelerates cathode cracking, whereas high pressure promotes lithium plating. Our findings highlight coupled mechanical–electrochemical degradation mechanisms and identify stack-pressure optimization as a practical solution for increasing cycling stability.