Laserline at the Battery Show Europe 2024 Energy-efficient laser applications for the e-mobility and battery industry

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This year, Laserline is focusing on High-Efficiency Diode Lasers for economical and environmentally-friendly battery drying. Also, the blue diode laser for effective processing of copper components is in the spotlight.

Laserline will be at the Battery Show Europe 2024 from June 18 to 20 in Stuttgart/Germany. There, the diode laser specialist will present energy-efficient laser applications for industrial material processing in the field of electromobility and battery manufacturing. Highlights of the trade fair appearance include the LDF-30.000-DR and LDF-15.000-DR diode lasers – two high-efficiency laser systems that are designed to support a diode laser-based drying process for efficient, economical and environmentally friendly production of lithium-ion batteries.

The process enables the production of anodes and cathodes in a roll-to-roll process for the first time. This provides an alternative to the dominant convection drying in electricity or gas powered continuous ovens. Compared to a conventional Giga-Fab drying line, it ensures a 28 percent saving in operating costs and a halving of the required production area. Thus, it represents an important milestone on the way to CO₂-neutral and competitive battery cell production.

The two models of the Laserline-LDF series are predestined for surface applications due to their precise, homogeneous Top-Hat beam profile with a width of up to 1.4 meters. They also offer output powers of 15 and 30 kilowatts respectively. The lower power class can also be upgraded to 30 kilowatts directly in the field after successful process establishment. According to the manufacturer, the high-efficiency lasers contribute to reducing process-specific CO₂ emissions. With an electrical efficiency of over 50 percent, they consume less energy than traditional industrial lasers, according to the company. They are therefore not only expected to lower operating costs, but also to contribute more to climate and environmental protection than any other laser tool.

Blue diode lasers

In addition, Laserline reportedly informs at the exhibition stand about its solution portfolio in the field of high-power blue diode lasers. One of the main applications is the welding of copper components, for example in electric drive technology or power electronics. Its wavelength of 445 nanometres is absorbed ten times better by copper and copper alloys than infrared radiation, which ensures exceptionally smooth melt pools without pore formation.

An application that is being presented for the first time is the removal of insulation layers on copper conductors with blue lasers. This uses the absorption property of short wavelengths in carbon compounds. The highlight of the product range are the world's first commercially available blue diode lasers with 4 Kilowatt CW output power. These open up new areas of application, such as deep welding of inverter assemblies. At the exhibition stand, the most compact variant of high-performance blue diode lasers is presented: The LDM-blue lasers are available with CW output powers up to 2 Kilowatts and, according to the manufacturer, their space-saving 19 inch format (7 units high) can be easily integrated into machine and system concepts.

Laser welding, with its reduced, adaptable heat input, is also suitable for industrial material processing tasks as pure laser beam welding. Using welding filler materials, such as those used in the production of battery boxes, they should also be suitable. In addition, the diode laser-based process supports numerous possibilities for beam shaping. With their help, the power input can be individually adapted to the respective component. As a result, according to Laserline, there is less hot cracking.

At the trade fair stand, an addition of welding filler materials as cold or hot wire will be presented. This offers further advantages such as the optimization of welding speed and mechanical-technological properties, in addition to bridging tolerances. Laserline will demonstrate the advantages of the interaction of laser technology and welding filler material supply - such as reduced rework - using battery box profiles.

Laserline at the Battery Show Europe 2024: Hall 8, Stand 8-A57.