Enabling Safer Li-ion Batteries with Less Flammable Electrolytes using 3-D Electrode Architectures

Problem: The flammability of conventional lithium-ion battery (LIB) electrolytes poses a persistent and significant safety hazard, particularly in demanding military applications where batteries may be subjected to extreme conditions, including puncture, crushing forces, and high temperatures. Such events can lead to thermal runaway and catastrophic fires, endangering the lives of soldiers and compromising mission success. Simultaneously, increasing the energy density of LIBs remains a crucial objective for extending the operational capabilities of various military equipment. Higher energy density translates to longer runtimes for soldier-worn devices, extended flight times for unmanned aerial vehicles (UAVs), and increased runtime for ground vehicles, all of which are vital for enhancing mission effectiveness and reducing logistical burdens.Proposed Solution: This Phase I SBIR project addresses this critical challenge by developing safer, high-energy-density LIBs. We will achieve this by integrating Arbor Batteries' patented 3-D electrode architectures with less-flammable electrolytes. Our innovative laser ablation process (TRL 4) creates a network of microchannels within the electrodes, effectively increasing their surface area and optimizing the transport of lithium ions. Importantly, our laser patterning process is compatible with existing Li-ion manufacturing lines, facilitating seamless integration and rapid scaling. We will utilize high-energy-density Gr/Si blend electrodes optimized for the Conformal Wearable Battery (CWB). To enhance safety, we will employ less-flammable electrolytes based on fluorinated solvents. These electrolytes, while significantly reducing the risk of fires, often exhibit higher viscosity, which can limit ion transport and hinder battery performance. However, the enhanced ion transport pathways created by the microchannels in our 3-D electrodes will be used to offset the lower diffusivity of these electrolytes, enabling the development of safe, high-performance batteries that meet the stringent requirements of military applications.