State-of-Charge-Dependent Deformation and Electrochemical Evolution in Sodium-Ion Batteries Under Mechanical Compression

Sodium-ion batteries (SIBs) are emerging as attractive electrochemical energy-storage systems owing to the natural abundance and low cost of sodium resources. However, their structural integrity and electrochemical stability under mechanical abuse remain insufficiently understood, particularly from the perspective of coupled morphological and transport responses in porous electrode assemblies. In this work, the material deformation behavior and electrochemical evolution of SIBs under compressional loading are systematically investigated, with particular attention to the roles of state of charge (SOC), electrode microstructure, and separator integrity. Electrochemical impedance analysis reveals that the ohmic response is mainly dominated by the extent of compressional deformation, whereas interfacial and diffusion-related resistances are jointly regulated by deformation and SOC. In particular, elevated SOC significantly intensifies the increase in diffusion impedance during compression, indicating a strong coupling between sodium-storage state and mass-transport deterioration. Moreover, cells at higher SOCs exhibit accelerated open-circuit voltage decay during extrusion, suggesting enhanced internal stress accumulation and aggravated instability of the electrode/electrolyte interface. Post-mortem morphological characterization demonstrates substantial particle fracture, pore collapse, and crack propagation in both cathode and anode materials, accompanied by severe shrinkage and partial destruction of the separator microporous network. These results establish a direct correlation between compressional deformation, microstructural damage, and electrochemical degradation in SIBs, and provide useful insights for the design of mechanically resilient electrode architectures, separator materials, and safety-oriented diagnostic strategies for next-generation sodium-ion energy-storage devices.