Cell teardown and characterization of an automotive prismatic LFP battery

A key challenge in lithium-ion battery research is the need for more transparency regarding the cell design and production processes of battery as well as vehicle manufacturers. This study comprehensively benchmarks a prismatic hardcase LFP cell that was dismounted from a state-of-the-art Tesla Model 3 (Standard Range). The process steps and manufacturing peculiarities were traced by disassembling the cell and analyzing the characteristics on the material level. A butterfly-design with two jelly rolls was found for the cell design in order to minimize the void volume (6.4%). Cross-sections and microscopy analyses from the cell cap revealed the application of multiple laser-welding processes that are needed to provide a high stability and tightness. The coatings of the approximately 22 m long electrodes showed a high homogeneity with thickness fluctuations less than 2 µm. Scanning electron microscopy images revealed a pure graphite anode and a bimodal particle distribution within the lithium iron phosphate cathode, whereby the edges of the cathode were covered in a 27 µm thick aluminum oxide (Al₂O₃) insulation layer. Electrochemical analyses were performed showing the improved performance of the inherent electrolyte over a common LP572 electrolyte. A gravimetric energy density of 163 Wh/kg and a volumetric energy density of 366 Wh/l was determined based on a nominal cell capacity of 161.5 Ah. Overall, the purpose of this work is to demonstrate which design decisions and manufacturing challenges are addressed in industrial cell production, so that the focus of academic research can align with the state-of-the-art.