Coating defects

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Areal loading

How much active material, or capacity, an electrode carries per square centimetre of foil, typically 2–5 mAh/cm². Higher loading raises energy density but lengthens the ion path, which limits fast charging.

Coating

Applying slurry to the moving foil at a controlled wet thickness, usually with a slot die, often on both sides. Coating weight per area must be held within about one percent across the web, because every downstream property depends on it.

Electrode wrinkling and buckling

Out-of-plane waves or folds in an electrode. In production they come from calendering, where the coated area stretches more than the bare foil edge, and from uneven web tension in winding; in service, electrode expansion can buckle a tightly wound jelly roll. Wrinkles leave uneven gaps and pressure that cause local lithium plating or separator damage.

Lithium plating

Lithium metal depositing on the negative-electrode surface instead of intercalating into it. It is promoted by charging at low temperature or high current.

Mixing

Dispersing active material, conductive carbon and binder in solvent to a uniform slurry with the right viscosity for coating. Order of addition and shear history matter: poorly dispersed carbon leaves particles electrically stranded.

Slurry rheology

How an electrode slurry flows under stress, measured as viscosity against shear rate on a rheometer. A good slurry is shear-thinning: thin under the high shear of the coating head, thick at rest so particles do not settle and the wet film does not spread before it dries. Rheology is the main check that mixing produced a stable, coatable slurry.

References & further reading

Further reading on this topic

These sources provide broader context; they are not presented as citations for every statement in this entry.

1. Current and future lithium-ion battery manufacturing

   Yangtao Liu, Ruihan Zhang, Jun Wang, Yan Wang · iScience · 2021

   Topic background · Electrode preparation, cell assembly, formation and manufacturing trade-offs.