Lasers Drive e-Mobility Innovation from Battery Cells to Automobiles

Laser manufacturer Luxinar is showcasing its laser applications for every step of the battery production process, from cell to car, at The Battery Show Europe. CO₂ laser sources and femtosecond lasers that can shape battery cells and refine electronic components will be presented for the first time on stand 4-G58 from 18 to 20 June in Stuttgart, Germany.

Luxinar’s battery cell applications include cutting separator foils and cutting and notching electrodes. Battery module and power train applications comprise e-vehicle battery casing ablation and busbar isolation stripping and trimming, and e-mobility applications include electric motor hairpin coating removal. We outline below one of the many ways that lasers can contribute to battery manufacturing and carbon footprint reduction.

Unwrapping non-conforming or used prismatic battery cells by laser

Prismatic cells in automotive applications are frequently wrapped in a self-adhesive PET heat shrink film. This film might need selective removal to add heat management components to the bare metal of the can or complete removal to rework non-conforming cells in the production cycle. Finally, when the battery is recycled at the end of its life, the film needs to be removed.

Currently, most of the above processes are done manually by cutting the foil with knives and scraping it off before wiping off the residues with solvents. This mechanical and chemical process leaves a clean but scratched surface.

Moving over to non-contact laser processing allows partial or full automation of the process and handling cells of different shapes and sizes in high volumes. A Luxinar OEM 45iX CO₂ laser source ablates the film and leaves an invisible and very thin layer of sticky residue on the bare metal surface, needing post-process treatment.  However, the residue can be removed by simply wiping with isopropanol, so the laser process removes the need for harsh solvents and intensive mechanical effort.

Christian Dini, Commercial Manager – Central & Northern Europe of Luxinar, stated: “We are thrilled to be showcasing our laser sources for the first time at The Battery Show Europe. Luxinar has been mastering lasers since 1998, and the versatility and precision of our laser technology make various battery production tasks economically viable."