So far we have followed the electrons to each particle. The ions must reach the particles too, and for that we must look at the space between them. An electrode is not a solid block. It is a composite: particles of active material, often wired together by a conductive additive such as carbon,9 held by a binder, with about 30 % of its volume left as pores that the electrolyte fills.1 Every ion that reaches a particle has travelled through those pores, and two numbers describe them.
Porosity: how much room
The porosity is the fraction of the electrode’s volume that is pore. It is well defined and easy to find.10 We weigh a disc of the coating and measure its thickness. From the masses and densities of the solid ingredients we get the volume the solids fill, and whatever is left of the coating’s volume is pore.10
Freshly coated electrodes are then pressed, or calendered, to lower their porosity. That packs more energy into each litre and improves the electronic contact through the coating and to the current collector; typical lithium-ion electrodes end at roughly 30 %.10
Tortuosity: how far round
The pores do not run straight across. An ion has to wind round the particles, so its path is longer than the coating is thick, and the channels narrow and widen on the way. The tortuosity collects these effects. In its simplest, geometric sense it is the length of the path divided by the straight distance. The tortuosity that matters for transport, the effective tortuosity, also includes the changing cross-section and the rough surfaces; it is found by measurement, or by simulation on a three-dimensional image of the electrode.10
Together the two numbers set how well the electrolyte conducts inside the coating, . The ratio , the MacMullin number, says how many times worse the filled pores conduct than the free liquid.10 Battery models often take the tortuosity from the porosity alone, with the Bruggeman relation , which gives .10 The modelled cell in the next figure uses exactly this correction, for diffusion as well as for conduction.11
Measuring it, and why it matters
How is measured? One clean way builds a cell from two identical electrodes and fills it with a salt that cannot react with them or enter the particles, so that no charge crosses into the particles and the ions can only charge the pore walls. The impedance spectrum then follows a transmission line, a ladder of resistances along the pores and capacitances at their walls that we meet again in Lab 4. Fitting it gives the ionic resistance of the pores, and for the pair of electrodes , with the area and the thickness of one electrode.10
Measured this way, real electrodes are worse than the estimate. In one systematic study, every electrode tested had a MacMullin number larger than the Bruggeman relation predicts, by about 1.5 to 3 times in the authors’ summary and by more in some of their fits (figure 11.5). The measured curves fall with porosity at roughly the same power as the estimate, exponents of 1.1 to 1.6 against 1.5, but start three to five times lower.10 A graphite electrode of porosity 0.43 gave , about three times the estimate of 1.5 (the fitted graphite curve in figure 11.5, drawn through electrodes of many porosities, runs a little lower than this single point). Graphite’s plate-like particles lie flat in the coating and hinder the way across: at similar porosities, electrodes of round NMC particles had MacMullin numbers of 10 to 11, against 18 to 19 for graphite. Particle size and the amount of conductive carbon matter too.10
Worked example. Let us find the porosity of a coating and what it leaves of the electrolyte’s conductivity. Take an illustrative NMC coating 50.0 µm thick with 15.6 mg of solids per cm
2: 96 % NMC (density 4.7 g/cm
3), 2 % carbon (2.2 g/cm
3),
10 and 2 % binder, for which we assume 1.8 g/cm
3.
solids per cm2:
coating per cm2:
porosity: 0.30
estimate: 0.16
measured graphite: 0.10,
Even by the estimate the coating keeps only a sixth of the liquid’s conductivity; the measured graphite electrode keeps a tenth, not the 28 % the estimate gives it.
measuring the porosity and tortuosity of a coating
Porosity, from a balance and a thickness gauge.
- Punch discs of the electrode, 11 mm across in one study.10 Punch discs of the bare current-collector foil too: their mass and thickness are subtracted, because we want the coating alone.
- Weigh each disc on a microbalance (1 µg resolution in that study) and measure its thickness with a precision gauge. Thickness was the weaker measurement there: about ±2 µm, that is 4 to 10 % of a coating 20 to 50 µm thick, against ±0.01 mg/cm2 for the mass.10
- From the composition and the bulk density of each ingredient, compute the volume of the solids and the porosity, , as in the worked example above.10
Tortuosity, from an impedance spectrum.
- Build a symmetric cell from two electrodes of closely matched loading and porosity, with a separator between them, in a T-cell or a pouch cell.10
- Fill it with a salt whose ions cannot react with the electrodes or enter them, such as tetrabutylammonium perchlorate in EC:DMC, so that no charge crosses into the particles. Measure the conductivity κ of this electrolyte separately at the same temperature.10
- Record the impedance around open circuit, for example from 200 kHz to 0.5 Hz with a 10 mV perturbation, at 25 °C.10
- Fit a transmission-line model with constant-phase elements, or extrapolate the low-frequency branch and the high-frequency intercept to the real axis: the gap between them is .10
- Compute ; the 2 is there because the spectrum holds both electrodes.10
Worked numbers: two graphite electrodes, each 63.2 µm thick with porosity 0.41 and an effective area of 2.37 cm2, in an electrolyte of 1.74 mS/cm, gave for the pair.10 So , with lengths in cm and κ in S/cm, close to the 4.3 ± 0.6 the study reports for graphite electrodes of porosity about 0.43.
This is why the two numbers matter. At high rates the performance of a cell is largely set by the ionic resistance of its electrodes and separator, filled with electrolyte, and porosity and tortuosity are the key to that resistance.10 Pressing a coating therefore cuts both ways: more material in each litre, but less room for the ions and a longer way round. The next figure shows what happens when the ions run short.
Porosity says how much room the ions have, tortuosity how far round they must go; together they divide the electrolyte’s conductivity inside the coating.