THE OUTCOME The MTC used laser surface micro-texturing and an optimised laser setting to produce a new, micro-textured demonstrator battery that performs better under extreme conditions. The optimised battery showed a 32% improvement in the surface adhesion leading to a more robust and safer cell compared to the off-theshelf Li-ion battery. As a result of this project, the MTC has identified a high value manufacturing process that is a viable and scalable, alternative method to the current ‘Roll-to- Roll’ manufacturing process of the cells.
BENEFITS TO THE CLIENT Through utilising an advanced laser-based surface engineering process, alongside the expertise of experienced researchers and engineers, the MTC has successfully demonstrated the positive impact that lasers can have on the performance of battery cells in extreme environments. The integration of laser surface micro- texturing on the production line could also save time and make a vital performance change leading to the removal of calendaring from the current process and the use of more powerful lasers as surface texturing technology matures, improving the overall quality of Li-ion battery manufacturing. Further to this, the MTC identified that this innovative process could be used to lengthen the life span of the battery and enhance how the cell manages heat by focusing on the texturing of the battery housing to allow the cell to charge under higher currents. The project has also shown that laser surface microtexturing could provide wider benefits to other high value manufacturing industries. This process to improve the bond strength of adhesives could boost heat conduction in sectors where high- performance, thermal management units are used such as the aerospace, automotive and defence arenas. It could also support anti- fouling systems on propellors in the marine sector by creating surfaces with well-defined structures that are better for the environment and reduce pollution. Overall, the creation of this new Li-ion battery demonstrator has shown that laser- based engineering processes could be vital to the development of Li-ion battery cells, and it has provided the MTC with an opportunity to work with its membership to explore how lasers could further influence UK manufacturing.
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