Lithium plating induced by anode tab tearing in lithium-ion batteries: An experimental and modeling study

Manufacturing defects are potential causes of thermal runaway in batteries, which poses serious safety risks in electric vehicles and energy storage systems. Tab tearing, one common defect that can occur during battery manufacturing process, can result in battery safety hazards. However, there has been little research on the impact of tab tearing defects on battery safety. This study compares the impact of different types of tab tearing defects, and concludes that complete tearing of the anode tab poses the most significant hazard to battery safety. Specifically, the study investigates the lithium plating phenomenon caused by the anode tab tearing defect, and identifies its corresponding mechanisms. The study finds that the complete tearing of anode tab causes lithium plating at the anode edge, which is more likely to occur at low charging currents. This result is unexpected, as it had been previously thought that high charging currents cause lithium plating. The study analyzes the mechanism behind the lithium plating phenomenon and identifies two main factors: (1) high electrolyte-phase electrical potential at the anode edge during charging, and (2) gradual accumulation of the amount of lithium intercalation at the anode edge during cycling. The study's results broaden the understanding of the impact of tab tearing defects and the causes of lithium plating.