Fragmentation of copper current collectors in Li-ion batteries during spherical indentation

Large, areal, brittle fracture of copper current collector foils has been observed by 3D x-ray computed tomography (XCT) of a spherically indented Li-ion cell. This fracture is hidden and non-catastrophic to a degree because the graphite layers deform plastically, and hold the materials together so that the cracks in the foils cannot be seen under optical and electron microscopy. The cracking of copper foils could not be immediately confirmed when the cell is opened for post-mortem examination. However, 3D XCT on the indented cell reveals “mud cracks” within the copper layer and an X-ray radiograph on a single foil of the Cu anode shows clearly that the copper foil has broken into multiple pieces. This failure mode of anodes in Li-ion cell has very important implications on the behavior of Li-ion cells under mechanical abuse conditions. The fragmentation of current collectors in the anode must be taken into consideration for the electrochemical responses which may lead to capacity loss and affect thermal runaway behavior of the cells.