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

ĀĀ Arbor Batteries has developed a patented manufacturing technique for Li-ion Battery (LIB) electrodes that enables a significant reduction in charging times (0-90% in 10 min), while simultaneously increasing energy density and safety without compromising cell cost or cycle life. This enhancement arises from our novel LIB cell design featuring 3D electrode architectures, produced via laser manufacturing. Our process has generated substantial interest in both the military and commercial sectors; however, achieving the manufacturing speeds essential for full-scale military or commercial adoption remains a challenge. Herein, we propose adapting our manufacturing process for compatibility with high throughput manufacturing. The primary objectives of this project are: Evaluate and select high-power lasers and high-speed optics, verifying their compatibility with our 3D manufacturing process. Integrate selected components into a high-throughput lab scale system demonstrating a 10x increase over our current manufacturing speeds. Manufacture multilayer pouch cells for in-house and third-party testing to validate the efficacy of the new manufacturing system in producing 10-minute fast-charging cells. The proposed laser manufacturing processes is drop-in compatible with todayÆs LIB manufacturing and can be directly integrated into high-speed roll-to-roll electrode manufacturing lines, enabling us to scale rapidly at a low cost.