Utilizing laser technology to modify the architecture of electrodes within lithium-ion batteries holds significant promise for enhancing battery performance, particularly in achieving stable and high-power outputs while maintaining elevated electrode loading [1]. By selectively ablating sections of the electrode, additional space is created for electrolyte infiltration, thereby enhancing its penetration throughout the electrode’s thickness and facilitating improved wettability. This mitigates local electrolyte depletion during high-rate cycling, consequently enhancing overall battery longevity [2]. Furthermore, the augmented surface area resulting from laser ablation facilitates more efficient electrochemical reactions, reducing the average current density during cycling and optimizing material utilization while minimizing the risk of detrimental side reactions.

Numerous studies have focused on electrode laser ablation, targeting either the anode, cathode, or both electrodes. Across these investigations, improvements in electrochemical performance metrics such as available capacity, rate capability, and cycling stability have consistently been observed following laser surface patterning [3]. Nevertheless, the process is not without downsides: although laser pulses are of extremely short duration, the intense heat produced during the structuring process can trigger side reactions on the surface of the remaining particles [4]. This phenomenon predominantly affects cathode materials, potentially leading to a subsequent reduction in attainable capacity and cycling stability.

In this work, we performed the ablation of nickel-rich cathodes (LiNi0.83Co0.12Mn0.05O2), setting limits of active mass loss during the laser processing to avoid an excessive decrease of the cell capacity and assessing the outcomes of the process with optical and electron microscopy. We then investigated the electrochemical behavior of cathodes with two different structuring strategies in coin cells, three-electrode cells, and bi-layer pouch cells (ca. 140 mAh). Despite an observed improvement in rate performances, the preliminary results of the study suggest that the laser structuring may damage the active material and induce the formation of resistive interfaces, highlighting the need to find optimal laser parameters to avoid detrimental side reactions during the structuring process.
 

References

[1] Pfleging, W. A review of laser electrode processing for development and manufacturing of lithium-ion batteries. Nanophotonics 7, 549–573 (2018).

[2] Pfleging, W. Recent progress in laser texturing of battery materials: a review of tuning electrochemical performances, related material development, and prospects for large-scale manufacturing. Int. J. Extrem. Manuf. 3, 012002 (2020).

[3] Hung, C.-H., Huynh, P., Teo, K. & Cobb, C. L. Are three-dimensional batteries beneficial? Analyzing historical data to elucidate performance advantages. ACS Energy Lett. 8, 296–305 (2023).

[4] Lutey, A. H. A., Fiorini, M., Fortunato, A. & Ascari, A. Chemical and microstructural transformations in lithium iron phosphate battery electrodes following pulsed laser exposure. Appl. Surf. Sci. 322, 85–94 (2014).