Benefits of Femtosecond Laser 40 MHz Burst Mode for Li-Ion Battery Electrode Structuring

In Li-ion batteries, ion diffusion kinetics represent a limitation to combine high capacity and a fast charging rate. To bypass this, textured electrodes have been demonstrated to increase the active surface, decrease the material tortuosity and accelerate the electrolyte wetting. Amongst the structuring technologies, ultrashort pulse laser processing may represent the key option enabling, at the same time, high precision, negligible material deterioration and high throughput. Here, we report a study on the structuring of electrodes with both holes and grooves reaching the metallic collector. Electrochemical models emphasize the importance of hole and line dimensions for the performances of the cell. We demonstrate that we can control the hole and line width by adjusting the applied fluence and the repetition rate. In addition, results show that it is possible to drill 65 µm-deep and ~15 µm-wide holes in nearly 100 µs resulting in up to 10,000 holes/s. To further reduce the takt time, bursts of 40 MHz pulses were also investigated. We show that bursts can reduce the takt time by a factor that increases with the average power and the burst length. Moreover, at comparable fluence, we show that bursts can shorten the process more than theoretically expected.