Hierarchical structuring of high-capacity electrodes (HiStructures)

Project duration:
01.10.2019 – 30.09.2022


  • Center for Solar Energy and Hydrogen Research Baden-Württemberg (ZSW), Accumulators Materials Research (ECM)
  • TU Braunschweig, Institute for Particle Technology (iPAT)
  • TU Braunschweig, Institute of Joining and Welding (ifs)
  • KIT, Institute of Thermal Process Engineering / Thin Film Technology (TFT)
  • University of Ulm, Institute of Stochastics
  • DLR, Institute of Engineering Thermodynamics, Department Computational Electrochemistry at the Helmholtz Institute Ulm for Electrochemical Energy Storage (HIU)
  • TU Braunschweig, Institute of Energy and Process Systems Engineering (InEs)
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Universität Ulm
Technische Universität Braunschweig

Research on Lithium-ion batteries is a decisive step towards electromobility and for a low-emission future. A special challenge is the manufacturing of cost-effective an efficient battery cells. A successful implementation in industrial application is expected by a higher energy density reached by a modified manufacturing process of the Lithium-ion cells. A promising approach for increasing the energy density are ultra-thick high capacity electrodes. For this purpose, the elaboration of a comprehensive understanding of structuring concepts is an important step.

The project HiStructures addresses questions impeding the implementation of ultra-thick electrodes. Their drawbacks are a low mechanical quality and rate capability. The project objective is a significant increase of energy density by double-side coated ultra-thick electrodes and the reduction of the correlating decline of power. This should be achieved by adopted processes and tailored structuring of the electrodes. At the same time, material and manufacturing related costs are intended to be reduced. Furthermore, an abundant concept for manufacturing will be elaborated.

Within the project, ZSW investigates the manufacturing and structuring of the cathode. TU Braunschweig elaborates the concept for the manufacturing and structuring of the anodes. Coating and drying analysis will be performed at KIT and TU Braunschweig. Research on the simultaneous double-side coating of the electrodes will be done at KIT. Finally, at ZSW a concept for full cells consisting of ultra-thick cathodes and anodes will be researched. In parallel to the experimental work, stochastic 3D-structure models of Ulm University, structure-resolved electrochemical simulations of DLR and modelling and optimization by homogenized structure models of the TU Braunschweig will be elaborated.
The project supports a technology leadership of a large-scale battery production in Germany by innovative, sustainable production concepts. These should contribute to expand the competence for LIB and develop further the industrial competitiveness in Germany.