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Lithium-ion batteries are currently one of the most important energy storage devices for various applications. However, it remains a great challenge to achieve both high energy density and high-power density while reducing the production costs. Cells with three-dimensional electrodes realized by laser ablation are proven to have enhanced electrochemical performance compared to those with conventional two-dimensional electrodes, especially at fast charging/discharging. Nevertheless, laser structuring of electrodes is still limited in terms of achievable processing speed, and the upscaling of the laser structuring process is of great importance to gain a high technology readiness level. In the presented research, the impact of different laser structuring strategies on the electro-chemical performance was investigated on aqueous processed Li(Ni0.6Mn0.2Co0.2)O2 cathodes with acid addition during the slurry mixing process. Rate capability analyses of cells with laser structured aqueous processed electrodes exhibited enhanced performance with capacity increases of up to 60 mAh/g at high current density, while a 65% decrease in ionic resistance was observed for cells with laser structured electrodes. In addition, pouch cells with laser structured acid-added electrodes maintained 29–38% higher cell capacity after 500 cycles and their end-of-life was extended by a factor of about 4 in contrast to the reference cells with two-dimensional electrodes containing common organic solvent processed polyvinylidene fluoride binder. [ABSTRACT FROM AUTHOR]

An increase in the energy density on the cell level while maintaining a high power density can be realized by combining thick-film electrodes and the 3D battery concept. The effect of laser structuring using different pattern types on the electrochemical performance was studied. For this purpose, LiNi0.6Mn0.2Co0.2O2 (NMC 622) thick-film cathodes were prepared with a PVDF binder and were afterward structured using ultrafast laser ablation. Eight different pattern types were realized, which are lines, grids, holes, hexagonal structures, and their respective combinations. In addition, the mass loss caused by laser ablation was kept the same regardless of the pattern type. The laser-structured electrodes were assembled in coin cells and subsequently electrochemically characterized. It was found that when discharging the cells for durations of less than 2 h, a significant, positive impact of laser patterning on the electrochemical cell performance was observed. For example, when discharging was performed for one hour, cells containing laser-patterned electrodes with different structure types exhibited a specific capacity increase of up to 70 mAh/g in contrast to the reference ones. Although cells with a hole-patterned electrode exhibited a minimum capacity increase in the rate capability analysis, the combination of holes with lines, grids, or hexagons led to further capacity increases. In addition, long-term cycle analyses demonstrated the benefits of laser patterning on the cell lifetime, while cyclic voltammetry highlighted an increase in the Li-ion diffusion kinetics in cells containing hexagonal-patterned electrodes. [ABSTRACT FROM AUTHOR]