Li-ion Batteries with Improved Charge Rate, Energy Density, and Safety, using 3D Structured Electrodes

Arbor Batteries has developed an advanced Li-ion battery (LIB) manufacturing process aimed at addressing current limitations in energy density, charge rate, and safety. Our technology utilizes a patented laser patterning process to create 3D structured electrodes, enabling extreme fast charging (0-90% in 10 minutes) while simultaneously increasing energy density and safety without compromising cost or cycle life. This process is compatible with existing LIB manufacturing infrastructure, facilitating rapid and cost-effective scale-up. Our technology, currently at Technology Readiness Level TRL4, has been successfully prototyped to industrially relevant pouch cells.Laser patterning electrodes for LIBs creates rapid transport channels for Li ions, dramatically increasing the speed at which Li ions move into the electrode and enabling both faster charging rates and thicker electrodes. LIBs with thicker electrodes cost less and store more energy because they require fewer layers of metal foil and separator.In Phase I, we focused on adapting our manufacturing process for high-throughput compatibility. We achieved significant progress and surpassed all objectives. Key accomplishments include:Patterning Quality: We evaluated a wide range of lasers and optics, achieving system designs that surpassed geometry and consistency targets by more than three times.High-Throughput Process Demonstration: We developed a lab-scale high-throughput system that demonstrated a >20-fold increase in manufacturing speed.Battery Manufacturing and Testing: We manufactured multilayer pouch cells that demonstrated over 95% capacity retention after 100 cycles with 10-minute charging, exceeding the 80% target.During our techno-economic evaluation, we estimated electrode patterning costs to be less than 1% of the total cell cost. Additionally, enabling thicker electrodes can achieve a 30% decrease in inactive material, resulting in a 10% reduction in overall cost.The Phase II project aims to advance our 3D electrode technology from TRL 4 to TRL 6 by focusing on the following objectives:Enhance and Validate Roll-to-Roll Processing: Integrating and optimizing roll-to-roll (R2R) processing systems with laser patterning to ensure efficient, cost-effective production.Application-Specific Full Cell Formulations: Developing and optimizing cell formulations tailored for specific military applications, such as 6T battery packs for ground vehicles and high-energy-density cells for small UAVs.Low-Temperature Environment Testing: Enhancing fast charging and cold cranking performance in low-temperature environments to ensure reliable operation in critical military applications.Full System Prototype Testing: Integrating laser-patterned cells into full battery systems and testing them in operational environments to demonstrate significant performance improvements.