Micropillar-based channel patterning in high-loading graphite anodes for superior Li-ion batteries

This study presents a low-cost, one-step electrode patterning method that uses a template with micropillars to indent a hexagonal array of channels in high-loading graphite anodes for faster electrolyte infiltration and Li-ion transport. In contrast to prior studies on using laser micro-machining, active material losses could be completely avoided by the proposed methodology. The process can also be made roll-to-roll and continuous. Furthermore, the very small volume fraction of the introduced channels (<1 wt.%) has little impact on practically attainable energy density or specific energy. Yet, thus introducing pore channels significantly reduces electrolyte infiltration time and improves rate performance.