Model Prediction and Experiments for the Electrode Design Optimization of LiFePO₄/Graphite Electrodes in High Capacity Lithium-ion Batteries

<TEX>LiFePO₄</TEX> is a promising active material (AM) suitable for use in high performance lithium-ion batteries used in automotive applications that require high current capabilities and a high degree of safety and reliability. In this study, an optimization of the electrode design parameters was performed to produce high capacity lithium-ion batteries based on <TEX>LiFePO₄</TEX>/graphite electrodes. The electrode thickness and porosity (AM density) are the two most important design parameters influencing the cell capacity. We quantified the effects of cathode thickness and porosity (<TEX>LiFePO₄</TEX> electrode) on cell performance using a detailed one-dimensional electrochemical model. In addition, the effects of those parameters were experimentally studied through various coin cell tests. Based on the numerical and experimental results, the optimal ranges for the electrode thickness and porosity were determined to maximize the cell capacity of the <TEX>LiFePO₄</TEX>/graphite lithium-ion batteries.