The Form Factor Dilemma in High-Silicon Anodes: Structural Rigidity, Porosity Loss, and Plating Risk

AION Engineering INC While silicon (SiOx/SiC/Si) based anodes skyrocket battery capacity, their swelling character reaching up to 300% volume expansion transforms cell design from a purely electrochemical challenge into a brutal mechanical packaging problem. It is not just about how much lithium the active material can store; how the casing structurally resists (its rigidity) when … Read more

Tabbed vs Tabless Cylindrical Cells

tabless end of a cell

Cylindrical lithium-ion cells have long used metal tabs to connect the current collectors to the terminals. These tabs act as the path for current to flow out of the electrode layers and into the external circuit. While this design has been reliable for decades, it introduces a few well-known limitations, particularly for high power applications. … Read more

Cylindrical Cell Joining Methods

ultrasonic welding

Cylindrical cells are commonly joined using several methods, each with distinct advantages and disadvantages depending on the application. Here are the most popular methods: Spot Welding Description: Spot welding uses a controlled electrical current to create localized heat, fusing a nickel strip to the positive and negative terminals of the cells. World Electr. Veh. J. 2018, 9(2), … Read more