Impact of applied and preceding pressure on performance and reversible swelling of lithium-ion pouch cells with varying microporous separators

During the compression of battery cells in battery pack production, high forces occur temporarily due to the viscoelastic behavior of the cell components. The magnitude of these forces depends on the compression speed. Shortening the production time and, thus, increasing the compression speed is desirable for cost reduction. However, it must be ensured that the cells are not negatively affected by increased forces during production. The impact of these preceding forces, acting on the cell before operation, and the applied force during operation on the performance and the reversible swelling of 5 Ah NMC811/graphite lithium-ion pouch cells are investigated in this study. To this end, a universal compression testing machine was adapted to enable high-precision thickness measurements under defined constant pressure and temperature conditions. In addition, the effects of different microporous separators manufactured via dry process and wet process in an otherwise identical cell configuration were investigated. In the test procedure, the pressure was incrementally increased from 0.01 MPa to 2.5 MPa. Each measurement was performed at the distinct constant pressure levels, followed by a subsequent measurement at a reference pressure of 0.2 MPa to evaluate the impact of the preceding step. The results revealed that elevated preceding pressures on the cell can reduce the discharge rate capability on higher C-rates by up to 11%. The discharge rate capability of the cells with the wet-processed separator was more significantly influenced by increasing applied and preceding pressure than for those with the dry-processed separator. It was found that the reversible swelling of the cell was reduced by applying higher pressures, whereas elevated preceding pressure increased the reversible swelling. The results of this study suggest that cells should not be subjected to excessive forces before operation, for instance, during battery pack production, as this can negatively affect performance and swelling behavior. Furthermore, the mechanical stability of the separator during the pack production process should also be considered when designing a cell.