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Breakthrough in Lithium-Sulfur Battery Manufacturing via Laser Printing
A groundbreaking advancement in the production of lithium-sulfur batteries has emerged from a research team led by Prof. Mitch Li Guijun, an Assistant Professor in the Division of Integrative Systems and Design at the Hong Kong University of Science and Technology (HKUST). This team has introduced a single-step laser printing technique that streamlines the traditionally lengthy processes involved in manufacturing these batteries. Their research findings were recently published in the prestigious journal Nature Communications.
Lithium-sulfur batteries are viewed as the next generation of energy storage solutions, poised to replace conventional lithium-ion batteries due to their theoretically higher energy densities. The design of sulfur cathodes typically includes an intricate combination of active materials, host substances, and conductive components. However, producing these materials has often required elaborate, multistep procedures that can be both time-consuming and resource-intensive, raising concerns about production efficiency and cost-effectiveness.
To address these concerns, Prof. Li and his colleagues have pioneered a novel laser printing method that allows for the rapid and efficient manufacturing of integrated sulfur cathodes. This innovative approach utilizes high-throughput laser-pulse irradiation to activate precursor donors, resulting in the formation of jetting particles. These particles consist of halloysite-based hybrid nanotubes as host materials, sulfur as the active component, and glucose-derived porous carbon for conductivity. The resultant mixture is then printed onto carbon fabric, creating a cohesive sulfur cathode. Remarkably, the laser-printed cathodes exhibit exceptional performance in both coin and pouch variations of lithium-sulfur cells.
“In conventional battery manufacturing, the synthesis of active materials, the preparation of slurry mixtures, and the assembly of the battery components are typically handled separately under different conditions,” Prof. Li noted. “This often leads to processes that can take from a few hours to several days to complete.”
Prof. Li further elaborated on the efficiency of their new technique, stating, “Our advanced laser-induced conversion technology integrates these separate processes into a singular, rapid operation at nanosecond speeds. We can achieve a printing speed of about 2 cm² per minute using a single beam laser. For instance, a sulfur cathode measuring 75 × 45 mm² can be produced in just 20 minutes, capable of powering a small screen for several hours when integrated into a lithium-sulfur pouch cell.”
Dr. Yang Rongliang, the lead author of the study and a former postdoctoral fellow at HKUST, emphasized the technological innovation behind this research. He explained, “Our findings reveal fascinating interactions between lasers and materials. The laser-induced conversion can be described as an ultra-concentrated thermal event. During this process, the materials experience rapid heating and cooling, with temperatures potentially reaching thousands of degrees Kelvin. This leads to the decomposition and subsequent recombination of particles to form new materials. The extreme thermal conditions also promote micro-explosions that enhance the production and transport of these particles.”
Dr. Yang’s work was supported by contributions from Prof. Tang Aidong of Central South University and the China University of Geosciences, as well as Senior Engineers Li Tianbao and Tu Feiyue from the Changsha Research Institute of Mining and Metallurgy Co. Ltd. This research was funded by the Hong Kong Innovation Technology Commission (ITC) under project number MHP/060/21.
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