3D electrode architectures not only allow a rapid and homogeneous wetting of the electrodes with liquid electrolyte by choosing appropriate capillary patterns, but can also enhance electrochemical properties such as high-rate capability and cell lifetime, especially when the cells are operated at elevated C-rates.
Recently, various electrode designs based on lines, grids, holes, or hexagonal structures have been investigated for cathodes and anodes. However, most studies to date focused on the structuring of one electrode, and the electrochemical analyses are usually performed using a laser-structured electrode versus an unstructured electrode (full-cell) or Li foil (half-cell). Additionally, the laser ablation rates in the published works are still too low to match with typical roll-to-roll (R2R) coating line speeds of ≥30 m/min. Upscaling the structuring process using advanced and industrially reliable high-power ultrashort pulse (USP) lasers is crucial to pave the way of this new technology into the battery production and to TRL ≥ 6.
In the present work, NMC cathodes and graphite anodes are manufactured and subsequently structured using high-power ultrafast laser radiation. Besides, the mass loss of the electrodes is taken into consideration and the N/P ratio is kept constant to better compare the impact of the patterns on the electrochemical properties. Electrodes are then assembled into full-cells and electrochemical characterization is performed including rate capability analyses and lifetime analyses. Fast-charging ability, high-rate capability, lithium-plating analyses, and cycling stability of cells containing laser structured electrodes with different patterns were evaluated.