Lithium-ion batteries are widely used for many applications such as portable electronic devices and Electric Vehicles, because they have lighter weight, higher energy density, higher power density, and a higher energy-to-weight ratio than other types of batteries. Conventional contact-based cutting technology may be inefficient whenever cell design is changed since lithium-ion battery cells are not standardized. Furthermore, the conventional cutting may result in process instability and a poor cut quality due to the tool wear so that it leads to short circuits and local heat generation. These process instability and inefficiency may be solved by laser cutting due to advantages such as clean cutting edge, less deformation, applicability to almost all materials, possibility of precision processing, and easy modification of cutting path. Despite the importance of the laser cutting research, no clear definition of cutting widths has been presented, and there is lack of knowledge to understand the effect of laser parameters on cutting widths. Therefore, this research examines the surface of cathode cut by a laser and defines cutting widths such as top width, melting width, and kerf width. The relationship between the laser parameters and cutting characteristics with defined widths are studied. When the volume energy is less than 6.0172 × 10 10 J/m 3 , no active electrode material is removed. When the laser power is greater or equal to 100 W, both the top and melting widths are clearly observed. The laser power of 50 W can selectively ablate the active electrode material with the material removal rate of 32.14-55.71 mm 3 /min. The threshold volume energy to fully penetrate the 50 µm-thick current collector is between 9.6275 × 10 10 -8.0229 × 10 10 J/m 3 . All clearance width is less than 20 µm, while the clearance width interestingly exceeds 20 µm when the laser power is 200 W. The effect of material properties on heat transfer using the one dimensional transient semi-infinite conduction model is investigated. In addition, five types of physical characteristics are defined and discussed.
To reduce carbon emission, transportation sector has adapted lithium-ion battery-based hybridization of gasoline and diesel engines due to its efficiency, the availability of technologies, and nationwide infrastructures. To cut prismatic and cylindrical electrodes for lithium-ion batteries, die cutting and rotary knife slitting have been used. Both techniques have disadvantages such as tool wear, process instability, inconsistency of cut quality, and redesign of mechanical cutting processes due to various battery sizes. High speed remote laser cutting overcomes these disadvantages with characteristics such as contact-free process, high energy concentration, low noise level, fast processing speed, very narrow heat affected zone, applicability to nearly all materials, and flexibility of laser power. Optimization of key parameters, or power and scanning speed, has been presented for laser cutting of electrodes for lithium-ion batteries. An acceptable clearance width is observed. The line energy is defined as dividing laser power by scanning speed and spot size. A good quality of cut surface, with no defects, such as delamination, burrs, edge bending, or microsized material attachments, is achieved with line energies between 0.8 x 10(12) and 2.5 x 10(12) J m(-3) for anode and 0.31 x 10(12) Jm(-3) and less than 3.5 x 10(12) Jm(-3) for cathode
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