Hannover / April 17, 2023 - April 21, 2023
Hannover Messe 2023
Li-ion accumulators with liquid electrolyte are market-leading energy storage systems due to their wide range of applications and high energy densities. In the course of the energy transition, both the demand and the requirements for battery systems are very high.
These range from resource-saving, sustainable production to an increasing demand for higher energy and power densities. By integrating laser-based drying and patterning processes, Fraunhofer ILT offers innovative approaches in the roll-to-roll manufacturing process of lithium-ion batteries to meet the increasing production demands.
By using efficient diode lasers, the water-based electrode layers can be dried in a much more energy- and space-saving way than in complex hot-air oven processes. Furthermore, in the downstream laser structuring process, the power density and service life of the battery cells can be increased using ultra-short pulsed laser radiation. At the same time, industry-relevant process speeds are achieved through the combination with a multi-beam structuring module.
The production of electronic components using digital laser processes is more important than ever in the context of the megatrends Industry 4.0 and Internet of Things. Processes such as laser sintering, laser crystallization and laser lithography make it possible to meet the increasing demands on quality, quantities and costs of the manufacturing processes. But laser processes are also proving to be indispensable, particularly in terms of flexibility, component size and energy efficiency.
The new combination process Simultaneous Machining and Coating (SMaC) developed at the Fraunhofer ILT enables the combination of the EHLA coating process with a subtractive finishing step in parallel with the main production time, thus increasing productivity enormously. In addition to the economic advantages, the SMaC process also offers technological benefits compared to the conventional process chain. The process heat generated in the coating process leads to a softening of the material and thus to easier machining. This makes it possible to produce corrosion and wear protection coatings as well as functional surfaces more quickly and with less wear on the tools. SMaC technology offers considerable advantages, particularly when applying high-strength coating materials that are otherwise difficult to machine.
The Extreme Highspeed-Laser Material Deposition (EHLA) is a modified variant of the laser based directed energy deposition process. Characteristics of EHLA are high feed rates, low thermal input and flexibility of processable materials. With the origin as a coating technology the EHLA process was further developed to an additive manufacturing process by Fraunhofer ILT. This enables the combination of structure resolution and productivity for e.g. filigree components. Thin-walled aluminium components, which were produced in cooperation with ponticon GmbH, serve as an example exhibit.