Upscaling Advanced 3D Electrode Architectures for Fast Charging Batteries

Process upscaling of laser structuring of thick film composite electrodes has been pushed towards pilot-line level for the production of advanced 3D lithium-ion batteries. Fast charging performance is significantly improved for optimized 3D batteries, while lithium plating is substantially suppressed. In addition, capacity retention is dramatically increased and cycle life can be at least doubled. The 3D battery concept is demonstrated for both pouch and cylindrical cells and offers significant advantages in increasing energy density while reducing production costs. Roll-to-roll machine concepts using high-power ultrafast lasers have been established, enabling high rate and damage-free structuring of high mass-loaded electrodes.