Lasers4
Batteries

Driving e-mobility
from cells to cars
– laser applications forthe battery industry

Lasers4
Batteries

Luxinar's lasers
are used inmany battery
applications

In the complex processes underlying

From cells to cars, Luxinar’s laser sources

battery production, the laser stands out asplay a leading role in shaping battery cells

an indispensable tool for notching, slitting,or refining electronic components. The

surface functionalisation and many othernon-contact laser process eliminates

applications like the stripping of various

chemicals and production delays caused

kinds of isolator material or cutting of foils

by traditional tools, resulting in unmatchedand separators. Its versatility and precision

productivity.

make various tasks economically viable
and also expand the boundaries of what is
technically possible.

Lasers4
Batteries

Internal structure ofcylindrical battery
Anode: Mixed graphite compound on copper collector
Separator: Insulating layer to keep anode and cathode apart
Cathode: Mixed lithium compound on aluminium collector

Lasers4
Batteries

Case study:

Femtosecond laser surface structuring ofelectrodes for improved battery performanceBattery technology today is all about

Laser processing has the following

increasing power density, and laser

advantages:

processes are being developed to advancethis. At high power densities during
fast charging or discharging processes,
lithium separation is currently an issue.

• It is a precise process that
produces patterns with sub-micronresolution. This creates very highsurface area electrodes, leading toFemtosecond laser surface structuringsignificant improvements in battery(FLSS) uses ultrashort pulses of laser

performance.

light to introduce micropores into theactive layer of the battery electrodes, thus
mitigating the problem.

• It is a non-contact process, minimisingdamage to the electrodes. This enables
seamless integration of
microstructuring into existing battery
manufacturing processes.
• It is a relatively fast process that can
manufacture batteries on a large scale.

FLSS of a battery electrode minimises
lithium separation

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Batteries

Case study:

laser notching and slitting ofbattery electrodes using LXR®
fast-burst mode

Electrode slitting with LXR® 120-1030
in fast-burst mode

Laser cutting is a versatile non-contact

material – is a critical challenge in laser

The result is improved edge quality thatmachining process, crucial for several

cutting lithium-ion battery electrodes.

reduces the risk of electrical shorts andsteps in lithium battery electrode

Conventional lasers struggle with thisenhances the overall quality of battery

manufacturing. Typically it is used at thedue to their longer pulse durations,modules and packs.

slitting station to precisely divide the wide

creating a larger heat-affected zone (HAZ)

electrode coil (mother roll) into individual

around the cut, potentially damaging theelectrodes. Laser cutting is also used

separator or altering electrode material

in the separation (or notching) phase

properties, ultimately impacting battery

to achieve the electrodes' final desiredperformance.

shape.

Furthermore, thanks to a proprietary
LXR® fast-burst mode, high-speed
electrode cutting is achievable while
maintaining excellent edge quality. This
innovative technique utilises a 'burst' ofFemtosecond lasers offer a significant

USP pulses, delivering multiple pulses in

Maintaining a clean 'clearance width' – theadvantage by minimising heat transfer

rapid succession. This optimises cutting

precise width of the exposed middle layer

during cutting. Ultrashort pulse (USP)

speed without sacrificing the quality(typically aluminium or copper foil) after

durations of less than a picosecond

achieved with single-pulse processing.

cutting through the multi-layered electrodeproduce cleaner cuts with minimal HAZ.

Electrode cutting with LXR® 120-1030
in fast-burst mode (10x magnification)

Lasers4Batteries

Case study:

laser cutting battery separators –with or without a ceramic coating
Separator foils are made from plastic

Cutting these films by laser eliminatesfilm at thicknesses below 30µm; they are

dust and tool wear since laser cutting is acut to length mainly by mechanical cutters

non-contact process that does not apply

and prohibit short circuits between theforce to the thin film and coating.

electrically charged layers of electrodes.

CO2 lasers from the SR series, at a

Newer developments of battery separator

wavelength that is optimised to suit thefoils utilise a thin layer of a ceramic coating

material, have demonstrated excellent

applied to one side of the film. Cutting

cutting results across a variety of plastic

by knife increases wear on the tools, andfilm materials.

small ceramic particles chip off from thecutting edge, leading to dust pollution on
the film.

A laser does not create dust when cutting a ceramic-coated battery film

Lasers4
Batteries

Case study:

laser unwrapping of non-conforming
or used prismatic battery cells
Prismatic, like other format cells inNon-contact laser processing allows

automotive applications, are often

partial or full automation of the process

wrapped in a self-adhesive PET heat shrink

and handling of cells of different shapes

film. This film might need selective orand sizes in high volumes. A Luxinar OEM

complete removal:

45iX CO2 laser source is used with a galvo• to add heat management components 		

scanner to ablate the film, leaving only an

to the bare metal of the can• to rework non-conforming cells in the 		production cycle• to recycle the battery at the end of its 		
life
These processes are mainly done manually
by cutting the foil with knives and scraping
it off before wiping off the residues withsolvents. This mechanical and chemical
process leaves a clean but scratched surface.

A CO2 laser selectively ablates thewrapping of a battery cell

invisible, thin layer of residue on the baremetal surface that can be removed bysimply wiping it with isopropanol. The laser
process avoids the need for harsh solventsand intensive mechanical effort.
A three-axis scanner with one laser canprocess three surfaces, and two lasers witha scanner will process all six sides of thebattery. This is a fully automated process;it is not necessary to move the battery.

Battery pack containing prismatic battery cells

Lasers4
Batteries

Case study:

laser ablating busbars
Busbars in an electric vehicle

Busbars are made of metal, typically

Unlike mechanical methods, laser

Removal rates depend on the type andcopper or aluminium, and are used instripping and trimming are contactless,thickness of coating, as well as the coating

electric vehicles for power distribution

without ablation or loss of metal, andmethod (cross layer), but there is noand to connect high or low-voltage

with very little downtime or toolingmaterial loss (cost of copper or aluminium)

equipment in battery banks. They conduct

needed for any changes in product design.

with a CO2 laser. CO2 lasers such as thea large amount of electricity and have an
epoxy coating for insulation. This coatingmust be partially removed so that thebusbars can electrically connect to othercomponents in the vehicle.

A galvanometer scanner passes thelaser beam over the required area; inthis way, two lasers can process all sides
simultaneously while leaving the metal
undamaged.

OEM series can ablate a range of coating
materials at varying thicknesses quickly,
cleanly and flexibly.

CO2 lasers can remove enamel coatingfrom busbars

Lasers4
Batteries

Case study:

e-motor enamel ablation ofcopper hairpins by laser

CO2 lasers remove enamel coating fromcopper hairpins

Electric motor hairpin manufacturing
uses lasers as they are contactless, fastand no copper is lost

Electric motors use copper “hairpins” –Mechanical processes can damage thecontactless. Selective absorption means

Enamel removal using Luxinar's CO2 lasers

thick rectangular copper wires up to 6mm

surface of the copper and remove a thin

the coating is removed without damaging

is a very fast process. Removal rates

wide, which replace traditional copper

layer of expensive material. This createsthe copper, with very little downtime

depend on the type and thickness of thewindings. Hairpins are coated with awaste and increases the gap between

and no tooling needed to implement any

coating, as well as the coating method,

dielectric enamel (PEEK, PFA-PI, PA) tothe hairpins at the point where they mustdesign changes. A galvanometer scanner

but good results are generally possible.

provide electrical isolation; this enamelbe joined together, thereby hindering thepasses the laser beam rapidly over themust be partially removed, so that thewelding process. Mechanical stripping

required area, with the hairpin positioned

hairpins can be welded for electricalalso results in tool wear and breakages,

at an angle; in this way, two lasers cancontacting.

requiring frequent maintenance. Onprocess all sides simultaneously.

the other hand, laser processing is

While the MULTISCAN® lasers are well
suited to this application, 125-650W
lasers from the SR and OEM series may
also be used.

Lasers4
Batteries

Benefits oflaser processing vs.
mechanical processing:• Non-contact process increases productivity  
• No tool wear or breakage minimises downtime• Fewer chemicals and solvents reduce environmental impact• Digital process with lower tooling costs• High level of accuracy• Fast and consistent process reduces time to market• Flexible method that is easily automated  • Quick and easy implementation of design changes• Largely maintenance-freeLasers4
Batteries

MULTISCAN® HE/VS�125W

CO2 laser marking systems

The MULTISCAN® range of CO2 laser

The flexible software allows intelligent data

marking systems offers an inkless method

to be placed anywhere within the specified

of applying alphanumeric text, QR codes,

scan area, and the system can mark2D and traditional barcodes, as wellstationary objects or moving products

as complex graphics to a wide variety

which need to be coded on the fly.

of materials; marks can be made on
substrates including glass, plastics, wood,
paper, card, painted metals, and more.

• Clean, ink-free production lines• Static or on-the-fly marking, scribing
and drilling• Large scan area, up to 300x300mm• High-quality vector generation for
precise rendering of graphics• Low maintenance – fit and forget• Available in three wavelengths –10.6μm, 10.25μm and 9.3μm

Lasers4
Batteries

LXR® series

ultrashort pulse laser source

A new patented laser technology
from Luxinar.
The LXR® series incorporates innovativetechnologies and designs::• A large dynamic range of pulse
repetition frequencies and pulseenergies to enable application-specificoptimisation• A synchronisation signal for precise
control in dynamic applications• Burst mode and pulse-on-demand forefficient processing and application
optimisation• Detailed diagnostic/fault finding
information via: web interface, PCapplication, optional mobile control unit
• An integrated alignment beam andsafety shutter to ease integration• Wavelength options available at1030nm, 515nm and 343nm• An auxiliary drive unit as standard

Lasers4
Batteries

A watertight laser technology

SR series 80–250W
sealed CO2 laser sources

Our SR series CO2 laser sources are all IP66

rated to ensure a high level of protection

against water and dust ingress. This, together
with the reliability that our customers havecome to expect from Luxinar, guarantees awatertight laser technology.

• IP66 rating• Wavelengths 10.6µm, 10.25µm, 9.3µm• Integrated and field replaceable RF power
supplies• Compact, lightweight laser sources• Simple diagnostics• Minimum shipment power 20% higher
than rated power

The simple control interface and compact

mechanical design of the units allow easy
integration into laser-based processing
machines used for cutting, marking,perforating and drilling, among others.

Throughput, economy, flexibility and reliability
are the main features associated with the SR
series of CO2 laser sources.

Lasers4Batteries

OEM series 450–1000W
sealed CO2 laser sources
Power outputs up to1000W• Most lasers are available inwavelengths 10.6µm, 10.25µm, 9.3µm• Short optical pulse for improved edge
quality and minimal HAZ• A high quality, round, symmetrical beam
for high-speed processing applications• Minimum shipment power 20% higher
than rated power

The OEM series of CO2 lasers represents
a compact solution that can be easily
integrated into industrial processing
production lines. The RF power supply
enables the laser to produce short opticalpulses with high peak power or quasiCW output. There is also the option for
an absorbing thin film reflector (ATFR) to
prevent back reflection issues.

The OEM series lasers use a single
resonator design, producing laser lightwith a linear polarisation. With a beam
quality of K > 0.8, power and precision are
defining characteristics of these lasers.
Since many equipment manufacturerspurchase this range to integrate into theirequipment, these OEM laser sources areavailable without the laser housing, ifdesired.

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Batteries

Pre-sales technical support

Could a laser improve your manufacturing process?
Find out by sending us samples of your material or product to test in our labs. Luxinar’sengineers can carry out cutting, marking, engraving, drilling, scribing, ablation, and more
to replicate your application in the lab.
You’ll receive your processed sample within 10 working days and a detailed report ofour findings even sooner. You can also receive complimentary advice ranging from fumeextraction to sample positioning.
Whatever your process, we can help you to find the best laser for your application.

Contact us on https://www.luxinar.com/contact/ or info@luxinar.com
Follow us on social media:© 2024 Luxinar Ltd 903-0321-00 Rev1
Please note that while every effort has been made to ensure that the data given in this document
is accurate, due to a policy of continued improvement, the information, figures, illustrations, tables,specification and schematics contained herein are subject to change without notice.
LXR and MULTISCAN are registered trade marks (in the UK, EU and elsewhere) owned (in the UK,EU and elsewhere) by Luxinar Ltd, and must not be used without permission from the owner.

Luxinar Ltd
Meadow Road
Bridgehead Business Park
Kingston upon Hull
HU13 0DG UK
Tel: +44 1482 650088
sales.uk@luxinar.com
www.luxinar.com
Registered in England: 3477444