Electric vehicles (EVs) are key to reducing greenhouse gas emissions from the transportation sector, but they face some challenges in terms of battery performance and efficiency. A new battery manufacturing project, called BatMan, aims to address these challenges by using lasers to alter the microstructure of battery electrode materials.
BatMan, which stands for Battery Advanced Technology Manufacturing And Novelty, is a collaboration between the U.S. Department of Energy’s (DOE’s) National Renewable Energy Laboratory (NREL), Clarios, Amplitude Laser Group, and Liminal Insights. The project has developed a novel laser patterning process that uses ultrafast laser pulses to create pores and channels in the electrodes, which are thin layers of materials that store and release ions, the carriers of electric charge.
The laser patterning process can improve the performance and efficiency of EV batteries in several ways:
- It can increase the energy density of the battery by allowing thicker electrodes, which can store more ions, without compromising the charging speed or the battery lifetime.
- It can reduce the wetting time, which is the time it takes for the liquid electrolyte to soak into the electrodes, by creating pathways for the electrolyte to flow more easily.
- It can enhance the thermal management of the battery by creating channels for heat dissipation and preventing hot spots.
The BatMan project has demonstrated the laser patterning process at scale with state-of-the-art roll-to-roll manufacturing techniques, which can produce large quantities of electrodes at high speed and low cost. The project has also used advanced computational models and materials characterization techniques to optimize the design and performance of the patterned electrodes.
The BatMan project is part of the DOE’s Advanced Manufacturing Office (AMO), which supports innovative research and development of technologies that can boost the competitiveness of the U.S. manufacturing sector. The project is also aligned with the DOE’s Energy Storage Grand Challenge, which aims to accelerate the development and deployment of next-generation energy storage technologies.
The following table summarizes some of the benefits of the laser patterning process compared to the conventional electrode manufacturing process:
| Aspect | Conventional Process | Laser Patterning Process |
|---|---|---|
| Electrode Thickness | Limited by charging speed and battery lifetime | Increased by up to 100% |
| Energy Density | Limited by electrode thickness | Increased by up to 16% |
| Wetting Time | Long and costly | Reduced by up to 90% |
| Thermal Management | Prone to overheating and hot spots | Improved by heat dissipation channels |
