Laser texturing of Li-ion battery electrode current collectors for improved active layer interface adhesion

Nanosecond laser processing (NLP) is performed on aluminium and copper Li-ion battery (LIB) current collectors to improve the interface adhesion with active materials. The developed area ratio, Sdr, void volume, Vv, and maximum crater depth, h, are introduced to quantify the effectiveness and feasibility of NLP over a range of process parameters. By limiting the crater depth to half the foil thickness, increases in surface area of 20% and 13% are achieved on aluminium and copper foils of thickness 30 µm and 10 µm with a fluence of 24.8 J/cm2 and 49.5 J/cm2, respectively. The adhesion ratio of intact active material following peel-off tests on complete electrodes with textured current collectors is approximately 30% higher than with untreated current collectors.