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Solid-State vs Lithium-Ion Battery: Energy Density, Fast-Charge Dendrites and Thermal Margin Blender 5.2

Left: a conventional Li-ion cell (liquid electrolyte, graphite anode). Right: your choice of electrolyte and anode. Same cathode, same pack size, same charge. All figures are typical or assumed values, not product specifications.

Presets

Your cell

Charging and environment

Pack

Your cell and pack

Where the cell mass goes (mg per cm2 of electrode)

Plating / dendrite index vs C-rate

Li-ion referenceYour cellIndex 1 = limit
Index above 1: lithium plates on the anode instead of entering it (graphite), or the current exceeds the critical current density (lithium metal).

Pack hot spot during a 10 to 80 % charge

ReferenceYour cellSelf-heating onset (dashed)

Heat generation vs cooling (your pack)

Heat generated (I2R + exotherm), kWCooling UA (T - Tcoolant), kW

Self-checks

Same pack energy, same charge rate and temperature for both cells.

Driving range

Experiment 1: how fast can each cell charge without plating or dendrites?

Sweeps the C-rate from 0.1 to 4 at the current temperature and finds where the index crosses 1, for the reference and for your cell. The numerical crossing is compared with the closed-form limit.
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Experiment 2: how does temperature move the fast-charge limit?

Sweeps -20 to 50 C and plots the maximum plating-free C-rate. Cold slows ion transport and the interface (Arrhenius), so the limit collapses in winter.
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Experiment 3: does a bigger pack keep adding range?

Sweeps the pack from 20 to 150 kWh. A heavier pack raises the energy per kilometre, so range gains flatten; a denser cell flattens later.
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The science
Educational model. Material numbers are typical, rounded or assumed; solid-state batteries are still emerging and published results vary widely between laboratories. Nothing here describes a particular company or product.

Energy density from capacity, voltage and inactive mass

Cell energy is E = Q · V. Per cm2 of electrode the cathode stores q = 4 mAh/cm2 and the average cell voltage is about 3.65 V (graphite) or 3.78 V (lithium metal), so E = q V in mWh/cm2. Specific energy is Wh/kg = 1000 E / m where m is the sum of every layer: cathode coating, anode, copper and aluminium foil, electrolyte and separator, pouch and tabs. Volumetric energy is Wh/L = E / thickness. Only the active materials store energy; the rest is overhead. A lithium-metal anode replaces roughly 90 um of graphite coating by about 23 um of lithium, which is the main gain; a solid electrolyte layer is thinner than a wetted separator-plus-pores stack but needs more catholyte in the cathode (lower active fraction) and usually stack-pressure hardware.

Pack level

A pack holds the cells plus cooling, busbars, casing and electronics. Here the cell-to-pack factors are 70 % by mass and 55 % by volume for both cells. Pack mass = E_pack / (Wh/kg · 0.70).

Fast charging and lithium plating

1C means charging the cathode areal capacity in one hour: j = C q in mA/cm2. In a graphite anode the surface potential is phi = phi_eq - eta, with eta = j · ASR(T) and ASR(T) = ASR25 · exp[Ea/R (1/T - 1/298)]. When phi drops below 0 V against Li/Li+ (near 80 % state of charge phi_eq ~ 0.08 V), lithium plates as metal. The plating index is eta / phi_eq; the limit is C_max = phi_eq / (ASR · q). Cold raises ASR exponentially, so the safe C-rate collapses in winter.

Dendrites and critical current density

For lithium metal the index is j / j_crit(T). Above j_crit lithium deposits unevenly into needles. The toy growth law is dL/dt = v0 (r - 1)^1.5 while charging; the cycles to an internal short are L_electrolyte / (growth per cycle). Solid electrolytes are stiffer but not immune: filaments follow grain boundaries and voids, and published critical current densities are a few mA/cm2 at best, often lower. The numbers used here (0.8, 3.0 and 2.0 mA/cm2 at 25 C for liquid, sulfide and oxide) are assumed round values; the key message is that solid-state lithium-metal cells can be more limited in fast charging than liquid graphite cells, not less, unless the interfaces are engineered.

Heat generation and thermal margin

Pack heat from resistance is P = I² R with I = C · Ah_pack and R_pack = (n_series/n_parallel) · ASR(T) / area. Cooling removes UA (T - T_coolant), UA = 18 W/K per kWh. The lumped temperature obeys C_th dT/dt = I²R(T) - UA (T - T_c); with R constant the solution is T = T_c + (P/UA)(1 - e^(-t/tau)), tau = C_th / UA. The hot spot is assumed 1.4 times the mean rise. The margin is the self-heating onset temperature minus the hot-spot temperature; onset values (liquid ~100 C, sulfide ~140 C, oxide ~180 C, 15 C lower with lithium metal) are assumed. Above onset a toy exotherm q0 exp[(T - T_onset)/15 K] is added, and the diagram shows where generation beats cooling for good. Solid electrolytes remove the flammable organic liquid, but cathode-electrolyte reactions and lithium-metal reactivity still release heat.

EV range

At constant 90 km/h: F = m g C_rr + 0.5 rho C_d A v², electrical power F v / 0.90 + P_aux, with auxiliary 0.6 kW plus 0.1 kW per degree below 15 C (heating) or 0.06 kW per degree above 25 C. The vehicle is a 1250 kg glider + 100 kg payload + the pack. Range = 0.90 · E_pack · f_cold / (Wh/km). Cold also reduces usable capacity (assumed 0.30 to 0.50 % per degree below 25 C).

Independent numerical checks

  • Energy = capacity x voltage, rebuilt from active-material masses and specific capacities.
  • Mass budget: all parts sum to the cell mass; pack Wh/kg x kg = kWh.
  • I²R: RK4 integration with fixed R equals the closed-form exponential; the real run conserves heat (generated = stored + removed).
  • C-rate limit: closed form equals bisection.
  • Range x Wh/km = usable energy.

Simplifications

  • One representative NMC cathode; no silicon swelling, cycle ageing, calendar fade or state-of-charge dependence of resistance.
  • The dendrite law is a qualitative-quantitative toy, not a validated electro-chemo-mechanical model.
  • One-node thermal model; real packs have gradients, coolant heating and propagation between cells.
  • Solid-state energy-density values are projections for emerging cells; commercial lithium-ion cells span a wide range around the reference.
  • Foil thicknesses in 3D are exaggerated; the labels give real micrometres.
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