Gaining a New Technological Readiness Level for Laser-Structured Electrodes in High-Capacity Lithium-Ion Pouch Cells

For the first time, the laser structuring of large-footprint electrodes with a loading of 4 mAh cm−2 has been validated in a relevant environment, including subsequent multi-layer stack cell assembly and electrochemical characterization of the resulting high-capacity lithium-ion pouch cell prototypes, i.e., a technological readiness level of 6 has been achieved for the 3D battery concept. The structuring was performed using a high-power ultrashort-pulsed laser, resulting in well-defined line structures in electrodes without damaging the current collector, and without melting or altering the battery active materials. For cells containing structured electrodes, higher charge and discharge capacities were measured for C-rates >1C compared to reference cells based on unstructured electrodes. In addition, cells with structured electrodes showed a three-fold increase in cycle lifetime at a C-rate of 1C compared to those with reference electrodes.