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<p>Conventional battery electrodes exhibit high tortuosity, which severely impedes ion transport. This limitation restricts electrode thickness, decreases power density, and shortens battery lifetime. Fabricating through-holes can reduce tortuosity, but existing methods are generally complex with poor space utilization. Here, an array of high-density through-holes are fabricated by temporally shaped ultraviolet femtosecond laser. Using this technique, we achieve a 47:1 aspect ratio (6 μm in diameter), ensuring low material loss (&lt;1%) for 280 μm-thick LiFePO<sub>4</sub> (LFP) electrodes. The through-hole array reduces tortuosity of LFP thick electrodes by 19.1% (30 mg cm<sup>-2</sup>), 19.0% (40 mg cm<sup>-2</sup>), and 20.2% (60 mg cm<sup>-2</sup>), improving the specific energy density of batteries by 9.39%, 12.27%, 17.39% at 1 C, 1.5 C, and 2 C, respectively. It also boosts LFP power density by 100%–200% and doubles the cycling lifetime. This work demonstrates an effective approach for fabricating low-tortuosity thick electrodes, enhancing comprehensive performance of batteries.</p>

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Fabrication of low-tortuosity thick electrodes with low material loss by temporally shaped ultraviolet femtosecond laser

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2025年12月23日

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  • Junrui Wu,
  • Huixin Guo,
  • Ruoxi Wang,
  • Lan Jiang,
  • Xin Li,
  • Jiang Zhang,
  • Richen Jia,
  • Mengyao Tian,
  • Yu Liu,
  • Xiaofeng Wang,
  • Ran Zhao,
  • Xiangbiao Liao,
  • Qian Cheng

摘要

Conventional battery electrodes exhibit high tortuosity, which severely impedes ion transport. This limitation restricts electrode thickness, decreases power density, and shortens battery lifetime. Fabricating through-holes can reduce tortuosity, but existing methods are generally complex with poor space utilization. Here, an array of high-density through-holes are fabricated by temporally shaped ultraviolet femtosecond laser. Using this technique, we achieve a 47:1 aspect ratio (6 μm in diameter), ensuring low material loss (<1%) for 280 μm-thick LiFePO4 (LFP) electrodes. The through-hole array reduces tortuosity of LFP thick electrodes by 19.1% (30 mg cm-2), 19.0% (40 mg cm-2), and 20.2% (60 mg cm-2), improving the specific energy density of batteries by 9.39%, 12.27%, 17.39% at 1 C, 1.5 C, and 2 C, respectively. It also boosts LFP power density by 100%–200% and doubles the cycling lifetime. This work demonstrates an effective approach for fabricating low-tortuosity thick electrodes, enhancing comprehensive performance of batteries.