Processing of Advanced Battery Materials—Laser Cutting of Pure Lithium Metal Foils

Jansen, Tobias; Blass, David M.; Hartwig, Sven; Dilger, Klaus

doi:10.3390/batteries4030037

Cited by 15 publications

(10 citation statements)

References 6 publications

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“…Similarly, lasers are applied to the processing of an extensive range of materials, from metals, ceramics, plastics, composites, glasses, thin films, and anodised surfaces through to perhaps more unexpected materials such as wood [43], leather [44], cotton [45], dough [46], and even egg shells [47]. Laser materials processing is applied in almost all manufacturing industries, including aerospace, automotive, electronics, batteries, medical, 3-D printing, semi-conductors, sensors, and solar [48][49][50]. Similarly, size scales vary from that of welding ship steel [51,52] down to materials processing near the diffraction limit [53][54][55][56][57].…”

Section: Introductionmentioning

confidence: 99%

Lasers that learn: The interface of laser machining and machine learning

Mills

Grant-Jacob

2021

IET Optoelectronics

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Laser machining is a highly flexible non-contact fabrication method used extensively across academia and industry. Whilst simulations based on fundamental understanding offer some insight into the processes, both the highly non-linear interactions between laser light and matter and the variety of materials involved mean that theoretical modelling is not particularly applicable to practical experimentation. However, recent breakthroughs in machine learning have resulted in neural networks that are capable of accurate and rapid modelling of laser machining at a scale, speed, and precision well beyond those of existing theoretical approaches with applications including 3-D surface visualisation and real-time error correction. A perspective at the intersection of laser machining and machine learning is presented, followed by a discussion of future milestones and challenges for this field.10 steps each, that corresponds to a total of 10^5 experimental trials. Because of the often highly non-linear relationships amongst parameters, the standard practice is generally the systematic collection of laser-machining data for all parameter combinations to identify the optimal combination. However, this process is both time-consuming and unfocussed and can take days or weeks, hence costing unnecessary effort, time, and money. Even when the optimal parameters have been determined, small changes during manufacturing, for example in laser power or beam shape, can result in final product quality that is below the required standard, again with associated costs in time and money. What is needed, therefore, is a set of modelling methodologies for identifying optimal parameters and providing real-time monitoring and error correction during manufacturing.However, the processes that describe laser machining, such as the light-matter interaction, heat conduction, phase change of material, and material removal, are particularly complex and hence challenging to model precisely and directly from a theoretical standpoint. The exact details of these processes depend on many factors, including laser parameters (e.g. wavelength, fluence, and pulse length), associated diffraction effects, and sample properties (e.g. absorption, reflectivity, melting temperature, and ablation threshold). In addition, different interaction effects become dominant as the temporal interaction length varies from continuous wave to ultrafast (i.e. femtosecondThis is an open access article under the terms of the Creative Commons Attribution License, which permits use, distribution and reproduction in any medium, provided the original work is properly cited.

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Section: Introductionmentioning

confidence: 99%

Lasers that learn: The interface of laser machining and machine learning

Mills

Grant-Jacob

2021

IET Optoelectronics

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“…For high cutting‐edge quality, lasers with short pulse widths that allow for minimized HAZ are preferred. [ 138,140,142 ] A reasonable compromise between achievable cutting speed, reduction of thermal damage, and investment costs is laser with a pulse width in the nanosecond area (1–250 ns). [ 138,140 ] In comparison with continuous wave lasers, cutting speeds are lower.…”

Section: Challenges In the Upscaling Of Battery Cell Productionmentioning

confidence: 99%

The Role of Pilot Lines in Bridging the Gap Between Fundamental Research and Industrial Production for Lithium‐Ion Battery Cells Relevant to Sustainable Electromobility: A Review

2021

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Despite intensive research activities on lithium‐ion technology, particularly in the past five decades, the technological background for automotive lithium‐ion battery mass production in Europe is rather young and not yet ready to meet requirements of automobile manufacturers. In light of the strong increase in electromobility, bridging this gap between fundamental research and industrial production is mandatory to keep the value chain of automobile manufacture in European countries. Challenges in know‐how transfer from lab scale to industry scale arise from different product configurations and objectives. Lab scale focuses primarily on material development and screening, utilizes small‐sized half‐cell or single‐layered designs with one‐side‐coated electrodes, and applies manually operated, discontinuous equipment, whereas industry focuses on optimized trade‐offs between throughput, quality, and costs. Market‐relevant cells contain usually double‐side‐coated electrodes with comparatively higher areal capacities, assembled into multilayered configurations. Mass production is conducted through automated, continuous processes including roll‐to‐roll manufacturing and consecutive pick‐and‐place operations. Inevitably, standard laboratory conditions do not allow for prediction of either optimized mass‐production process parameters nor physicochemical characteristics of final products. Hence, this Review aims to identify challenges in transferring lab‐scale results to industry with special focus on pilot lines as intermediate step between the different technological levels.

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“…However, this method is particularly suitable for small series production with changing battery formats because of the simple geometry change of the cutout by a modified beam guidance. For advanced battery materials with highly abrasive silicon particles or pure lithium metal with its low yield strength, die cutting reaches its limits due to wear and contamination of the cutting tool which leads to varying cutting‐edge qualities and therefore benefits laser beam cutting …”

Section: Introductionmentioning

confidence: 99%

Evaluation of the Separation Process for the Production of Electrode Sheets

et al. 2019

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The recent development of individual mobility is characterized by a resource‐saving and environmentally friendly technology policy. Electromobility has the greatest potential to meet these demands. Due to the high volumetric power density at both the cell as well as the battery levels, pouch cells are addressed as a target cell format. As a separation of the electrodes is absolutely necessary for this cell design, the separation of the electrodes constitutes a basic operation of the pouch cell production. The established separation methods, such as die and laser cutting, are compared in this work with regard to their physical cutting‐edge quality. For reproducible evaluation, the occurring cutting‐edge characteristics are defined to clearly describe the quality of the separated electrode. Furthermore, the influence of the photonically and mechanically produced cutting edge on the electrochemical performance is presented. The results show that the delamination of the active materials and the bending of the collector and the metal spatter have the greatest influence on the electrochemical performance of the cell.

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Processing of Advanced Battery Materials—Laser Cutting of Pure Lithium Metal Foils

Cited by 15 publications

References 6 publications

Lasers that learn: The interface of laser machining and machine learning

Lasers that learn: The interface of laser machining and machine learning

The Role of Pilot Lines in Bridging the Gap Between Fundamental Research and Industrial Production for Lithium‐Ion Battery Cells Relevant to Sustainable Electromobility: A Review

Evaluation of the Separation Process for the Production of Electrode Sheets

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