Applications of CO2 Lasers in the New Energy Sector
1. Cleaning of Coatings on Electric Vehicle Battery Housings:
Battery cells are often encased in self-adhesive PET shrink films, which may require selective or complete removal under certain circumstances: 1) when installing thermal management components on the battery pack's surface, 2) for reprocessing defective battery cells, and 3) during recycling at the end of the battery's lifespan. Typically, these processes involve manual cutting and scraping of the film material with tools, followed by solvent wiping to remove any residue. While this mechanical approach combined with chemical agents can achieve a clean surface, it often leaves scratches on the battery's exterior.
In contrast, non-contact laser processes can effectively handle battery cells of various shapes and sizes, enabling mass production and facilitating automation. CO2 lasers can remove the surface film material, leaving behind only a very thin layer of residue on the metal surface, which can be easily wiped off with isopropyl alcohol. Laser processing eliminates the need for harsh solvents and intensive mechanical methods. A galvanometer system equipped with a single laser can process three external surfaces of the battery, while a system with two lasers can handle all six external surfaces efficiently.
2. Laser Removal of Busbar Coatings:
Busbars, typically composed of copper or aluminum, serve as critical components for electrical transmission in electric vehicles, connecting high-voltage or low-voltage devices within the battery system. These busbars carry substantial electrical currents and are coated with epoxy for insulation. It is essential to partially remove this coating to enable proper connections with other components in the vehicle.
Unlike mechanical methods, laser ablation is a non-contact process that does not erode or damage the underlying metal, and it requires minimal downtime while preserving the integrity of the metal. This ensures efficient operation and reliability in the assembly of electric vehicle systems.
3. Laser Cutting of Battery Separators:
Battery separators, made from plastic films with a thickness of less than 30 microns, are primarily cut to the desired lengths using mechanical tools to prevent short circuits between electrodes. The latest advancements in separator technology involve applying a thin ceramic coating to one side of the film. However, using cutting tools can lead to increased wear, resulting in small ceramic particles detaching from the cutting edges and causing dust contamination on the film.
In contrast, laser processing is a non-contact method that effectively eliminates dust generated by traditional cutting techniques. This approach not only prevents tool wear but also ensures that the film and its coatings remain intact and undamaged, thus enhancing the quality and reliability of battery separators.
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