Product Code: ICAL08_701

Laser Processing for Alternatives Energy Devices: Advanced Battery and Fuel Cell Applications
Authors:
Hans Herfurth, Fraunhofer Center for Laser Technology (Clt); Plymouth MI USA
Rahul Patwa, Fraunhofer Center for Laser Technology (Clt); Plymouth MI USA
Henrikki Pantsar, Fraunhofer Center for Laser Technology (Clt); Plymouth MI USA
Golam Newaz, Wayne State University, College of Engineering; Detroit MI USA
Stefan Heinemann, Fraunhofer Center for Laser Technology (Clt); Plymouth MI USA
Presented at ICALEO 2008

Hybrid Electric Vehicles (HEVs) are a fast expanding global market, driven by consumer concerns about steadily rising gasoline prices, as well as growing public interest in low-emissions vehicles. Advanced batteries are an essential component of the HEVs as they assist in acceleration as well as operate the accessories in the vehicle. Currently dominated by NiMH batteries, Lithium-ion technology has significant potential for near-future HEV applications, because it offers further advantages regarding size, weight, cycle life and cost. Fuel cells are another example for an alternative energy device that has increasing applications as a both a stationary and mobile power source.

Although considerable progress has been made in the device technology with regard to efficiency and power output, efficient mass production remains a critical issue that must be resolved to further reduce the manufacturing cost and to meet the market demands for many applications. Laser processing can provide effective solutions in many stages of the assembly of these devices.

This paper will focus on cutting and welding applications for the assembly of Li-Ion batteries and PEM fuel cells. Copper and aluminum alloys are currently the dominating metals used to build Li-Ion cells, while stainless steel is favored for bipolar plates in PEM fuel cells. Examples for high speed cutting of foils and joining of similar and dissimilar materials using high brightness fiber and disc lasers will be given.