Optimization of External Pressure in Pouch Cell Manufacturing Through Large-Scale Phase-Field Simulation

Abstract Lithium metal batteries (LMB) have immense potential to transform a wide range of industries and applications due to enhanced energy density compared to the conventional lithium-ion battery. However, the widespread commercial application of LMB is impeded by the formation of lithium dendrites, which leads to high risk of short circuit and thermal runaway. While applying external pressure during cell manufacturing has been shown to be efficacious in suppressing dendrite growth, it may alter the separator’s porosity, tortuosity, and mechanical properties and inhibit the battery performance. Achieving the optimal balance between pressure, separator properties and battery performance is therefore essential. This paper developed a phase field model coupling electrochemical and mechanical properties to study the growth behavior of lithium dendrites under external pressure in the full cell. Through quantitative analysis of Li dendrite behavior under varying pressures, this study offers optimization strategies to mitigate trial-and-error cost during pouch cell manufacturing, ultimately extending battery lifespan and advancing performance.