Effects of momentum transfer on sizing of current collectors for lithium-ion batteries during laser cutting

One of the challenges of the lithium-ion battery manufacturing process is the sizing of electrodes with good cut surface quality. Poor cut surface quality results in internal short circuits in the cells and significant heat generation. One of the solutions that may improve the cut quality with a high cutting speed is laser cutting due to its high energy concentration, fast processing time, high precision, small heat affected zone, flexible range of laser power and contact free process. In order to utilize the advantages of laser electrode cutting, understanding the physical phenomena for each material is crucial. Thus, this study focuses on the laser cutting of current collectors, such as pure copper and aluminum. A 3D self-consistent mathematical model for the laser cutting, including fluid flow, heat transfer, recoil pressure, multiple reflections, capillary and thermo-capillary forces, and phase changes, is presented and solved numerically. Simulation results for the laser cutting are analyzed in terms of penetration time, depth, width, and absorptivity, based on these selected laser parameters. In addition, melt pool flow, melt pool geometry and temperature distribution are investigated.