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

Abstract 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.