Unraveling mechanisms of electrolyte wetting process in three-dimensional electrode structures: Insights from realistic architectures

The advancement of lithium-ion batteries (LIBs) towards larger structures is considered the most efficient approach to enhance energy density in clean energy storage systems. However, this advancement poses significant challenges in terms of the filling and wetting processes of battery electrolytes. The intricate interplay between electrode microstructure and electrolyte wetting process still requires further investigation. This study aims to systematically investigate the primary mechanisms influencing electrolyte wetting on porous electrode structures produced through different manufacturing processes. Using advanced X-ray computed tomography, three-dimensional electrode structures are reconstructed, and permeability and capillary action are evaluated as key parameters. It is observed that increasing calendering pressure and active material content reduces electrode porosity, thereby decreasing permeability and penetration rate; however, it simultaneously enhances capillary action. The interplay between these indicators contributes to the complexity of wetting behavior. Incomplete wetting of electrolytes arises from two primary factors elucidated by further simulations: partial closure of pores induced by the calendering process impedes complete wetting, while non-wetting phase gases become trapped within the electrolyte during the wetting process hindering their release and inhibiting full penetration of the electrolyte. These findings have significant implications for designing and optimizing LIBs while offering profound insights for future advancements in battery technology. • Systematic study of electrolyte wetting using advanced X-ray computed tomography. • Increased calendering pressure reduces porosity but enhances capillary action. • Active material content influences electrode permeability and wetting efficiency. • Partial pore closure and trapped gases hinder complete electrolyte wetting.