Establishing laser cutting of components for sulfide-based solid-state batteries

The demand for safe, power- and energy-dense, low-cost batteries is constantly increasing due to the global shift toward renewable energy sources and the associated need for battery electric vehicles and grid-level energy storage. However, current-generation lithium-ion batteries are struggling to meet the requirements and are reaching their physicochemical limits regarding energy density. Solid-state battery technology promises to improve the current state of the art in electrochemical energy storage and has proven itself in research, although not yet in commercial applications. One of the main challenges in bringing the technology to the market is the limited knowledge and research on the production of solid-state batteries with commercially viable technologies. This study investigates the application of laser cutting technology to improve the cutting process in the production of sulfide-based solid-state batteries. Challenges such as the production atmosphere, handling of the components, and differences compared to conventional battery components are discussed. Using a picosecond laser source, the influence of the pulse frequency, peak fluence, scanning speed, and laser passes was investigated to identify appropriate parameters for cutting sulfide-based composite cathodes. The findings were then successfully applied to the cutting of sulfide-based solid electrolyte separators. An improvement in edge quality compared to mechanical punching is demonstrated, marking a crucial step toward the commercialization of solid-state batteries.