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Research Article

Cite This: ACS Appl. Mater. Interfaces 2017, 9, 41284-41290 www.acsami.org

Development of Embedded Fiber-Optic Evanescent Wave Sensors


for Optical Characterization of Graphite Anodes in Lithium-Ion
Batteries
AbdulRahman Ghannoum,† Patricia Nieva,*,‡ Aiping Yu,† and Amir Khajepour‡

Department of Chemical Engineering, University of Waterloo, 200 University Avenue West, Waterloo, Ontario N2L 3G1, Canada

Department of Mechanical and Mechatronics Engineering, University of Waterloo, Waterloo, Ontario N2L 3G1, Canada

ABSTRACT: The development, fabrication, and embedment


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of fiber-optic evanescent wave sensors (FOEWSs) to monitor


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the state of charge (SOC) and the state of health (SOH) of


lithium-ion batteries (LIBs) are presented. Etching of
FOEWSs is performed using a solution of 40 wt % ammonium
fluoride (NH4F) and 49 wt % hydrofluoric acid (HF) (6:1),
which is found to be superior to an etching solution containing
just 49 wt % HF. FOEWSs were characterized using glycerol
and found to have the highest sensitivity in a lithium-ion
battery when they lose 92% of their transmittance in the presence of glycerol on their sensing region. The physical effect that the
FOEWS has on the graphite anode is also investigated and is found to be much more significant in Swagelok cells compared to
that in in-house-fabricated pouch cells, mainly due to pressure variation. The FOEWS was found to be most sensitive to the
changes in the LIB when it was completely embedded using a slurry of graphite anode material within a pouch cell. The
optimized fabrication process of the embedded FOEWS demonstrates the potential of using such sensors commercially for real-
time monitoring of the SOC and SOH of LIBs while in operation.
KEYWORDS: fiber-optic sensor, evanescent waves, fiber-optic etching, fiber-optic sensor characterization, lithium-ion batteries,
graphite anode, state of charge

■ INTRODUCTION
Lithium-ion batteries (LIBs) with their relatively high energy
rates on the acoustic measurements and further investigations
are needed to determine its viability in a commercial electric
density have supported the development of plug-in hybrid/ vehicle.
electric vehicles.1 A concern of every driver is the distance they The use of optical fibers to track volume/strain dynamics
can travel before the depletion of their energy source, within a LIB has also attracted researchers. Optical fibers with
promoting research on more effective and accurate battery Bragg gratings6 have been used as sensors for temperature and
monitoring systems (BMSs). The main goal of a vehicle’s BMS strain7 because Bragg gratings reflect a narrow band of
is to estimate the state of charge (SOC) and state of health wavelengths based on the grating period. This mechanism has
(SOH) of individual batteries in a battery pack to effectively been used to monitor strain in LIBs during cycling in hopes of
control the flow of current to achieve a specified optimum, such also using it as a SOC sensor. However, it requires a costly
as maximum battery life. Sensors are utilized to measure sensor interrogator to detect shifts in the wavelength.8
variables (e.g., voltage, temperature, and current flow) that can Optical fibers utilizing evanescent waves as a sensing
be correlated to the SOC and SOH. In addition to measuring mechanism have been used in various applications9−13 due to
voltage and current flow, research has extended toward their fast response, selectivity, and durability.14 A recent study
developing new sensing systems to measure internal material on the reflectance of commercial graphite anodes and fiber-
property changes to improve the accuracy in estimating SOC optic evanescent wave spectroscopy of electrochemically
and SOH and allow for early detection of cell failure.2−5 lithiated graphite demonstrated a correlation between lithiation
A recent study observed that acoustic ultrasonic waves and the transmittance through a fiber-optic evanescent wave
traveling through an operating battery experiences a shift in sensor (FOEWS).15 The spectroscopy results demonstrated
both amplitude and time of flight due to changes in the significant increase in transmittance in the near-infrared band
mechanical properties of the materials within a battery.4,5 (i.e., 750−900 nm) when graphite was lithiated electrochemi-
Coupling the acoustic measurements with voltage measure- cally. This illustrated that changes in graphite’s optical
ments in a machine learning model, the error of estimating
SOC was reduced to about 1% in a controlled testing Received: September 5, 2017
environment with equivalent cycle conditions.5 However, this Accepted: November 6, 2017
preliminary study did not examine the effects of varying charge Published: November 7, 2017

© 2017 American Chemical Society 41284 DOI: 10.1021/acsami.7b13464


ACS Appl. Mater. Interfaces 2017, 9, 41284−41290
ACS Applied Materials & Interfaces Research Article

Figure 1. Overview of the pouch cell with an optical fiber sensor preparation process starting with (a) optical fiber etching, then (b) spot welding of
the current collectors to the electrodes, and (c) stacking the battery components (laminated aluminum, cathode, separator, anode, and second
laminated aluminum layer). (d) Final assembled pouch cell with a connectorized FOEWS.

properties during lithiation can be observed using a FOEWS.15 THORLABS) with connectors (B10125A, THORLABS) attached.
This discovery resulted in the simplification of the FOEWS’s Glycerol (GX0185-2, EMD Millipore) was used to characterize the
interrogation system, whereby a photodetector sensitive to FOEWS’s etched cladding prior to battery testing. Swagelok cells and
near-infrared wavelengths can be utilized instead of a costly pouch/prismatic cells were fabricated using graphite and LiFePO4
electrodes (MTI Corp.) and a trilayer polypropylene−polyethylene−
spectrometer to monitor a LIB.16 The lithium content of a polypropylene membrane (Celgard) as a separator. As an electrolyte
graphite anode is directly related to the SOC of LIB. The for the batteries, a mixture of 1:1 (vol %) ethylene carbonate (BASF)
transmittance intensity of a FOEWS, which is affected by the and dimethyl carbonate (BASF) was used, with 1 M lithium
lithium content in graphite, can hence be used to estimate a hexafluorophosphate (Purolyte, Novolyte Technologies) as a salt. A
battery’s SOC. Capacity fade in a LIB results in a decrease in graphite electrode slurry was prepared for embedding the sensors,
the change of graphite’s lithium content; this results in a which consisted of 26% solids and 74% liquid. The solid mixture
decrease in the amplitude of the FOEWS’s transmittance. This consisted of 85% graphite (43209, Alfa Aesar), 10% poly(vinylidene
implies that the amplitude of the FOEWS’s transmittance can fluoride) (182702, Sigma-Aldrich), and 5% carbon black (Lib-SuperP,
be correlated to a battery’s state of health (SOH). MTI Corp.), whereas the liquid component contained 100% N-
The LIB environment can be considered a delicate but also a methyl-2-pyrolidone. An ethylene-vinyl acetate polymer-based hot
melt adhesive (PLIB-HMA8, MTI Corp.) strip was attached to the
chemically harsh environment containing an anode, a cathode, sensors to ensure a proper seal during pouch cell fabrication.
a separator, and an electrolyte. Overcharging, excessive external Sensor/Battery System Preparation. The optical fibers are
stress, and contamination due to poor assembly can all lead to initially stripped and etched in a polypropylene beaker (1201-0250,
capacity fade by allowing lithium deposition, electrode Nalgene), as seen in Figure 1a and described elsewhere.15,21 The
detachment, electrolyte decomposition (side reactions), or sensors are then tested using glycerol to determine the amount of
separator pore size reduction.17−20 Consequently, it is essential transmittance loss, as described in detail elsewhere.21 The Swagelok
that the assembly of a battery is studied and optimized when assembly configuration has been presented elsewhere.15 Sensors used
introducing a new component to the battery environment such in pouch cells had two hot melt adhesive strips (MTI Corp.) attached
as a fiber-optic sensor. In this article, we report the studies for about 3 cm from the center of the sensor to ensure a hermetic seal.
the development of a FOEWS, its embedment into a LIB, and The graphite/LiFePO4 electrodes are cut into 3 cm × 2 cm rectangles,
and 1 cm × 2 cm of active material is removed to obtain square
its performance characterization. Different etching solutions are electrodes (2 cm × 2 cm). The region with the removed electrode
studied in their ability to produce durable fiber-optic sensors. material is reserved for current-collecting tabs, which are spot-welded,
The method for embedding the FOEWS into the LIB and its as seen in Figure 1b. Aluminum tabs (PLiB-ATC4, MTI Corp.) are
characterization has been developed to ensure maximum used for the positive electrode (LiFePO4), and nickel tabs (PLiB-
battery cell life and improved sensor sensitivity. The minimal NTA3, MTI Corp.) are used for the negative electrode (graphite). The
capacity fade observed in all studied LIBs using the embedded electrodes are then used to sandwich a separator, and the sensor is
FOEWS also demonstrates its commercial feasibility. positioned between the graphite electrode and the separator. The stack


is then sandwiched between two laminated aluminum sheets (alf-100-
210, MTI Corp.), as seen in Figure 1c. Three sides are sealed using a
EXPERIMENTAL SECTION heat sealer (MSK-140, MTI Corp.). The open end is used for
Materials. The LIB sensor was fabricated using a step index electrolyte insertion inside a glove box and then sealed using a
multimode optical fiber (AFS105/125Y, Thorlabs) with core and compact vacuum sealer (MSK-155A, MTI Corp.). The pouch is then
cladding diameters of 105 and 125 μm, respectively. The fiber was placed on a three-dimensionally printed case to be held for testing, as
etched using both 49% hydrofluoric acid (HF, JT9564-6, VWR) and a seen in Figure 1d. Pouch cells with embedded sensors were prepared
buffered oxide etchant (JT5569-3, VWR). The FOEWSs were by placing the sensor on the graphite electrodes; a slurry of graphite is
connectorized using universal bare fiber terminators (BFTU, then poured on top to envelop the sensor and then left to air-dry in a

41285 DOI: 10.1021/acsami.7b13464


ACS Appl. Mater. Interfaces 2017, 9, 41284−41290
ACS Applied Materials & Interfaces Research Article

Figure 2. SEM micrograph of fiber-optic evanescent wave sensors (FOEWSs) etched using (a) concentrated hydrofluoric acid (49%) and (b)
buffered hydrofluoric acid (BHF) (6:1 ratio of ammonium fluoride to hydrofluoric acid).

Figure 3. FOEWS in two LIB configurations: (a) Swagelok and (b) pouch cell. Both the illustrated cells contained three layers: 1, graphite electrode;
2, separator; and 3, lithium iron phosphate (LiFePO4), with the fiber-optic sensor positioned on the graphite electrode.

Figure 4. SEM of a graphite anode extracted from a Swagelok cell that has completed two complete cycles, demonstrating the trench formed by the
presence of a FOEWS on the graphite electrode.

fume hood. The batteries are then cycled using an eight-channel Figure 2a, and circular pits with diameters ranging from 3 to 25
battery analyzer (BST8-WA, MTI Corp.), and the optical signal is μm were also observed.
recorded using a custom optical sensor interrogator with a narrow- Etching solutions consisting of 6:1 to 10:1 mixtures of 40 wt
band light-emitting diode concentrated at 850 nm connected to a
% ammonium fluoride (NH4F) and 49 wt % HF are utilized
computer, as described elsewhere.21


extensively to etch silica in the semiconductor industry and are
referred to as buffered HF (BHF).23 A 6:1 mixture (7.0 wt %
RESULTS AND DISCUSSION HF and 34.3 wt % NH4F) was tested and was found to produce
Fabrication of Fiber-Optic Evanescent Wave Sensors. FOEWSs that can withstand the LIB fabrication process. As
Etching of optical fibers using HF concentrations ranging from seen in Figure 2b, FOEWSs prepared using BHF were observed
48 to 52 wt % had been performed in the past to reduce the to have smoother surfaces. The observed difference between
fiber’s diameter.22 We first examined the use of a 49 wt % HF the two fibers is believed to be due to the variance in the
solution to etch the fluorine-doped silica cladding off the etching mechanism. The solution with a higher concentration
sensing region of the FOEWS. However, the resultant sensor of HF etches quicker23 and favors HF−2 reactions with silica.24
was fragile as it broke easily during handling and battery The second solution containing NH4F, however, had a higher
fabrication. In addition, the FOEWSs prepared using 49 wt % pH and favored HF reactions with silica over HF−2 during the
HF were found to have significant nonuniformity on their etching process.24 The mechanism resulting in the nonun-
surface, as seen by scanning electron microscopy (SEM) in iformity in the fabricated FOEWSs is beyond the scope of this
41286 DOI: 10.1021/acsami.7b13464
ACS Appl. Mater. Interfaces 2017, 9, 41284−41290
ACS Applied Materials & Interfaces Research Article

Figure 5. SEM micrographs of the region where the FOEWS was positioned (between the dotted lines) on the graphite anode extracted from (a) an
in-house pouch cell and (b) a Swagelok cell.

article, but the results indicate that using BHF solutions battery cycles, the applied pressure on the electrodes increases
produces FOEWSs with higher durability, increasing the during charge and decreases during discharge due to volume
throughput of the sensor/battery fabrication process. change.20 The assembled pouch cells were hence placed in
Fiber-Optic Evanescent Wave Sensor in LIBs. Two LIB custom housings to apply an initial pressure of 4 psi, promoting
configurations were used with the developed FOEWS and uniform current distribution and minimizing rippling of the
tested: (a) a Swagelok and (b) an in-house pouch cell, as shown electrodes, resulting in lower capacity fade.20 Using this in-
in Figure 3. house pouch cell configuration, a FCE of 87.2 ± 2.5% was
The Swagelok configuration allows for repeated testing of the achieved, which exceeded the performance of both the coin
same FOEWS because the cell can be disassembled and the cells and second-generation Swagelok cells with the same
electrodes can be replaced. We found that with careful electrode material. Electrodes from the in-house pouch cells
handling, a sensor can be tested up to three times within one were also examined using an SEM to determine the degree of
Swagelok cell. Theoretically, the FOEWS should not break but deformation caused by the presence of the FOEWS. As seen in
because the assembly takes place in a glove box, handling can Figure 5, the graphite electrode in the pouch cells did not
be difficult. The Swagelok cell has been reported to have a low undergo significant deformation as compared to that in the
first-cycle efficiency (FCE) of 72%, attributed to the higher- Swagelok cells, which demonstrates that the Swagelok cells
pressure conditions within the cell when compared to those in were cycling at a larger applied pressure, promoting an increase
other configurations such as coin cells.15 It is difficult to control in the rate of capacity fade. However, the area of the FOEWS
the applied pressure because it depends on the tightness of the interfacing with the graphite anode in the pouch cell is smaller
Swagelok nuts. However, decreasing the degree of turning because the deformation and indentation occurring in the
would increase the risk of contamination by air. Hence, a electrode are smaller, as seen in Figure 5.
second generation of Swagelok cells was fabricated by reducing To maximize the interaction between the FOEWS and the
the applied pressure and keeping them in an inert environment graphite electrode, a slurry of graphite was prepared to
to avoid air contamination. With these precautions, a FCE of completely embed the FOEWS (see Figure 6).
83.2 ± 3.00% was achieved, which is comparable to the
reported FCE of coin cells tested with the same electrodes.15
Graphite electrodes were extracted from the Swagelok cells
after cycling, and an SEM was used to observe the structural
effect that the FOEWS has on the graphite electrode. As seen in
Figure 4, a “trench” was formed on the graphite electrode in the
region where the FOEWS was positioned, covering about 1.7%
of the entire area. The increased strain in this trench is expected
to cause a variation in the performance of the electrode in the
region below the sensor compared to that in the bulk region.20
This variation may cause the sensor signal to represent only the
local region but can be correlated to the general SOC as the
local strain is constant. For preliminary testing, the Swagelok
configuration is considered ideal but not sufficient for long- Figure 6. SEM micrograph of the prepared graphite slurry for
term testing due to the observed capacity fade after multiple embedding the FOEWS.
cycles.
For improved pressure control and long-term testing and Embedding the sensor allowed for easier pouch cell assembly
packing efficiency, the pouch cell configuration shown in Figure because the sensor was fastened to the graphite electrode. In an
3b was chosen over prismatic and cylindrical cells. The industrial process, this would ensure a higher throughput in a
incorporation of a FOEWS requires the use of a polymer- production line. The three tested configurations are illustrated
based hot melt adhesive around the optical fiber’s exit points in Figure 7, where the sensor in the Swagelok cell sits deeper
from the pouch cell to avoid air from seeping into the pouch.21 into the graphite electrode when compared with the pouch cell,
Humidity in the air forms PF3O and HF from the electrolyte’s as observed by the larger trench in Figure 5. However, the
salt LiPF6, and HF would cause battery degradation.25 As a embedded sensor is positioned on top of the original electrode
41287 DOI: 10.1021/acsami.7b13464
ACS Appl. Mater. Interfaces 2017, 9, 41284−41290
ACS Applied Materials & Interfaces Research Article

Figure 7. Schematic illustration of the FOEWS positioning within the


graphite anode in (a) a Swagelok cell (based on Figure 5b), (b) a
pouch cell (based on Figure 5a), and (c) a pouch cell with added
slurry (Figure 6) to embed the sensor.

with a layer of added slurry to encompass the sensor’s diameter. Figure 8. Fiber-optic evanescent wave sensor sensitivity in relation to
The results from testing the three configurations are discussed the loss in 100% glycerol. The presented results include all three
in the next section. configurations, Swagelok cells, pouch cells, and sensors embedded
Fiber-Optic Evanescent Wave Sensor Transmittance within the graphite electrode in a pouch cell.
and Glycerol Testing. The fabrication of FOEWS for LIBs
requires a validation step to ensure that the etched optical fibers attributed to the variation in pressure between the cells because
are functional and sensitive to changes within the battery. Many the depth of the trench is dependent on the pressure applied
sensors were fabricated and tested with 100% glycerol to ensure during assembly. The deeper the trench, the larger the
that the optical fibers are not over-/underetched and to interaction between the FOEWS and the graphite electrode,
correlate the loss in glycerol to the sensor sensitivity in a LIB. increasing the sensitivity of the sensor. This also explains the
Transmittance through an optical fiber relies on the refractive reason why the sensors in the Swagelok cells had larger
index difference between the core of the fiber and the cladding sensitivity than that of those in the pouch cells, as seen by the
(i.e., the layer around the core); the core’s refractive index trench size difference in Figure 5. Embedding the sensor
needs to be higher than that of the cladding to allow total completely within the graphite electrode as illustrated in Figure
internal reflection to occur.6 Adding a temporary layer of 7c within a pouch cell resulted in the highest sensitivity, which
glycerol on the etched sensors would indicate if the cladding can also be seen when comparing the full cycle transmittance of
still exists on the fiber and the condition for total internal all three FOEWS positions (Swagelok cell, pouch cell, and
reflection still exists because glycerol’s refractive index (i.e., pouch cell with an embedded FOEWS) (see Figure 9). The
1.4656 at 850 nm26) is higher than the refractive index of the
sensor’s core (silica) (i.e., 1.4525 at 850 nm27). If a cladding
does not exist, 100% loss in transmittance is observed when
glycerol is placed on the etched fiber, which translates to a
sensor with no signal in a battery. Etched FOEWSs with about
85 to 96% loss in glycerol were tested in LIBs. To compare the
various cells, the LIBs were cycled from 0 to 100% SOC based
on the battery’s voltage limits (i.e., 2.5−3.7 V), while recording
the optical transmittance through a FOEWS. The sensor’s
baseline (i.e., transmittance at 0% SOC) differed between the
various batteries due to variation in the contact area, optical
fiber coupling, and cladding thickness. To compare the results,
the sensors’ sensitivities were determined using expression
[(transmittance at 100% SOC − transmittance at 0% SOC)/ Figure 9. Full charge and discharge transmittance for all three
transmittance at 0% SOC] and were correlated to the FOEWSs’ configurations: Swagelok, pouch, and pouch with an embedded sensor.
loss in glycerol (see Figure 8). The relative sensor signal change is equal to [(transmittance −
On the basis of the results in Figure 8, the Swagelok and transmittance at 0% SOC)/transmittance at 0% SOC].
pouch cells with and without embedded sensors demonstrated
the highest sensitivity when the sensor’s transmittance loss in relative sensor signal change was determined by shifting all
glycerol was about 92.0, 93.5, and 92.0%, respectively. transmittance measurements to start at 0 at 0% SOC and
However, because only two pouch cells with embedded sensors dividing the transmittance measurements by the initial
were tested, on the basis of the other two configurations, we transmittance at 0% SOC as a point of reference to permit
conclude that FOEWSs with about 92.0% loss in glycerol comparison between all three configurations.
achieve the highest sensitivity in a LIB. In the same figure, a The transmittance through the FOEWS was observed to
scatter was observed in the Swagelok cells’ results, which can be increase when the battery is charged in all three configurations
41288 DOI: 10.1021/acsami.7b13464
ACS Appl. Mater. Interfaces 2017, 9, 41284−41290
ACS Applied Materials & Interfaces Research Article

following a similar trend. The slope in the charging signal


significantly decreased as the battery approached 62.5% SOC;
■ ACKNOWLEDGMENTS
This work was financially supported by the “Green Intelligent
this may indicate the sensor’s limit of interaction with the
Transportation Systems (GITS)”Ontario Research Fund,
graphite particles, due to the sensing depth,28 or the decrease in
Canada, the “Next Generation Electric Vehicles: Development
lithiation activity in the local region29 of the FOEWS. During
of Key Technologies and Full Vehicle Testing”Natural
discharge, the transmittance was observed to decrease steadily
Sciences and Engineering Research Council of Canada
as lithium deintercalated, indicating a steady change in the
(NSERC)−Automotive Partnership Canada, and General
graphite particles surrounding the FOEWS during discharge
Motors. Special thanks to Liliana Zdravkova and Krishna Iyer
unlike charging. To investigate this further, a method to embed
for their contribution on the etching and the characterization of
multiple fibers within one graphite electrode in different
the optical fibers.


locations/depths is required for complete characterization of
the graphite anode. Nevertheless, the current observed trend in
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41290 DOI: 10.1021/acsami.7b13464


ACS Appl. Mater. Interfaces 2017, 9, 41284−41290

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