Stacking for energy storage devices

Abstract

A method includes obtaining a stack for an energy storage device, the stack including a substrate, a first electrode layer, a second electrode layer, and an electrolyte layer between the first electrode layer and the second electrode layer. The method includes laser ablating the stack to form a plurality of first grooves in the stack, each of the plurality of first grooves passing through the first electrode layer and the electrolyte layer. The method includes forming at least one registration feature in or on the stack that is different from each of the plurality of first grooves. An apparatus and stack for an energy storage device are also disclosed.

Description

Technical Field

[0001] The present invention relates to a stack for energy storage devices and more particularly, but not exclusively, to a method and apparatus for processing a stack for energy storage devices. Background Art

[0002] A known method of producing an energy storage device such as a solid-state thin-film battery comprising an electrode layer, an electrolyte layer and a current collector layer is to first form a stack comprising a first current collector layer, an electrode layer, an electrolyte layer, a second electrode layer and a second current collector layer formed on a substrate. The stack is then cut into individual parts to form individual cells. A protective layer may then be applied to each cell, for example, to prevent passivation of the layers and possible short circuits.

[0003] To make electrical connections with the cells, for example to electrically connect the current collectors of multiple cells stacked one on top of another, portions of the protective layer may be removed, for example by etching. Alternatively, a mask may be applied prior to the coating process to ensure that a portion of each current collector is exposed.

[0004] However, known formation and processing of stacks for energy storage devices such as solid-state thin film batteries can be inefficient, making efficient commercialization difficult. It is therefore desirable to provide efficient methods for forming and processing stacks for energy storage devices. Summary of the invention

[0005] According to a first aspect of the present invention, a method is provided, comprising: obtaining a stack for an energy storage device, the stack comprising a substrate, a first electrode layer, a second electrode layer, and an electrolyte layer between the first electrode layer and the second electrode layer; laser ablating the stack to form a plurality of first grooves in the stack, each of the plurality of first grooves passing through the first electrode layer and the electrolyte layer; and forming at least one alignment feature in or on the stack that is different from each of the plurality of first grooves. In an example, the alignment feature can be used to indicate a folding point at or towards which the stack will be folded. Alternatively or additionally, the alignment feature can be used to indicate quality control information of the stack.

[0006] Forming a registration feature that is different from each of the plurality of first grooves can allow efficient and reliable further processing of the stack, and therefore can allow efficient production of energy storage devices from the stack. For example, a registration feature for indicating a folding point at or towards which the stack is to be folded can allow efficient and reliable folding of the stack, and therefore allow efficient production of energy storage devices therefrom. For example, the registration feature can be easily identified by a folding machine or other device that folds the stack at or towards the identified registration feature, which can avoid the need for the folding machine or other device to perform complex (and therefore inefficient and potentially unreliable) analysis in order to determine where to fold the stack. Alternatively or additionally, the registration feature can be used to indicate quality control information for the stack. For example, the registration feature can indicate whether a given portion of the stack is below a quality control standard, and therefore whether the given portion of the stack should not be used or should be compensated when producing an energy storage device therefrom. This can allow reliable production of energy storage devices while reducing the need for quality control procedures during further processing of the stack, and therefore can allow efficient production of energy storage devices.

[0007] In an example, forming at least one registration feature includes laser ablating the stack to form at least one registration feature. Forming the registration feature and the plurality of first grooves by laser ablation may allow for efficient energy storage device production without requiring separate methods for forming the first grooves and the registration feature.

[0008] In an example, laser ablation to form the plurality of first grooves and laser ablation to form the at least one registration feature use laser light from a common laser source. This can allow efficient and cost-effective formation of registration marks and the plurality of first grooves, for example, compared to using separate laser sources to form the first grooves and the registration features.

[0009] In an example, the method includes changing the properties of the laser ablation used to form the plurality of first grooves to provide laser ablation for forming the at least one registration feature. This can allow for effective and efficient formation of registration features that are different from each first groove, for example, where the stack is processed in a continuous or near-continuous roll-to-roll type of processing.

[0010] In an example, changing the properties of the laser ablation includes changing the properties of a first laser used for laser ablation to form the plurality of first grooves to provide a second laser used for laser ablation to form the at least one registration feature. This may provide an efficient way to modify the properties of the laser ablation, for example, without modifying or interrupting the motion of the stack in a roll-to-roll process, which may allow efficient energy storage device production.

[0011] In an example, for at least one of the plurality of first grooves, laser ablation to form the groove exposes a surface of at least the first electrode layer; and wherein the method comprises: providing a monomer suspended in an inert gas in the region of the groove during laser ablation so that the monomer is polymerized onto the exposed surface of the first electrode layer. The polymerized monomer formed on the exposed edge can, for example, protect the exposed edge from degradation during subsequent processing of the stack. In some examples, the polymerized monomer can be an electrically insulating material. This can avoid direct electrical contact and thus short circuiting of the electrode layers of the stack during laser ablation and / or further processing of the stack. For example, using a laser beam for laser ablation to form the plurality of first grooves to polymerize the monomer onto the exposed edge can, for example, reduce the need to provide a separate deposition system to cover (e.g., electrically insulate) the exposed edge or avoid using a separate deposition system to cover (e.g., electrically insulate) the exposed edge. Additionally or alternatively, such a method can reduce the need to perform covering the exposed edge at different times, and thus can provide more efficient processing of the stack. Providing the monomer suspended in an inert gas can provide displacement of oxygen and / or moisture in the laser ablated region, which in turn can reduce the reaction tendency of the layer at the exposed surface during the laser ablation forming the first groove. The process can maintain the purity of the layer, which in turn can provide more reliable operation of the battery produced from the stack.

[0012] In an example, the method includes moving the stack in a first direction simultaneously or intermittently with the laser ablation for forming the plurality of first grooves or the at least one registration feature, and wherein each of the plurality of first grooves formed in the stack is elongated in a direction substantially parallel to the first direction. For example, this can allow the plurality of first grooves and / or registration features to be gradually formed by movement of the stack relative to a laser system performing the laser ablation. This can allow the first grooves and / or registration features to be formed relatively quickly and efficiently, for example in a continuous or near-continuous roll-to-roll type of processing of the stack.

[0013] In examples, one said registration feature is formed per a given number of adjacent first grooves in said plurality of first grooves. This may allow efficient segmentation of the stack into cells. For example, in examples where the registration feature indicates a folding point at or towards which the stack is to be folded, forming one said registration feature per a given number of adjacent first grooves in said plurality of first grooves may provide that subsequent folding of the stack will result in uniform lengths of the stack layers, which may allow efficient cell registration and thus cell segmentation.

[0014] In an example, the plurality of first grooves are formed sequentially, and the registration feature is formed after a given number of sequential first grooves in the plurality of first grooves are formed. Sequentially forming the first grooves and the registration feature can allow efficient and flexible formation of the first grooves and the registration feature, for example, in a continuous or near-continuous roll-to-roll type process of stacking.

[0015] In an example, the registration feature comprises a mark on the surface of the stack, which is a groove into the stack or a perforation in the stack, the groove being wider and / or deeper and / or having a different shape than each of the plurality of first grooves. The registration feature comprising a mark on the surface of the stack can allow efficient battery formation because less time and resources can be spent to form the mark on the surface of the stack than forming the groove or other registration feature through one or more layers of the stack. The registration feature is a groove in the stack that is wider and / or deeper and / or has a different shape than each of the plurality of first grooves, or a perforation in the stack, which can provide efficient energy storage device production because it can facilitate, for example, recognition of the registration mark by a folding device, and / or facilitate folding of the stack at the registration feature groove, for example by facilitating clean folding. The registration feature being a perforation in the stack can alternatively or additionally allow increased speed and therefore efficiency of laser ablation of the stack because, for example, it can take less laser ablation to form the perforation than a continuous groove.

[0016] In an example, the method further comprises: identifying a registration feature; and folding the stack at or towards the identified registration feature. Folding the stack at or towards the identified registration feature can allow for efficient and reliable folding, for example, without having to calculate the number of first grooves between each fold as part of the folding. Folding the stack can allow for efficient segmentation and production of relatively large capacity energy storage devices therefrom.

[0017] According to a second aspect of the present invention, there is provided an apparatus for processing a stack for an energy storage device, the stack comprising a substrate, a first electrode layer, a second electrode layer and an electrolyte layer between the first electrode layer and the second electrode layer, the apparatus comprising: a laser system arranged to: in use: laser ablate the stack to form a plurality of first grooves in the stack, each of the plurality of first grooves passing through the first electrode layer and the electrolyte layer; and wherein the apparatus is configured to: form at least one registration feature different from each of the plurality of first grooves in or on the stack. The registration feature can be used to indicate a folding point at or towards which the stack will be folded. This can allow efficient and reliable folding of the stack, and thus efficient production of energy storage devices. For example, the registration feature can be easily identified by a folding machine or other device that can then fold the stack at or towards the identified registration feature, which can avoid the need for the folding machine or other device to perform complex (and therefore inefficient and potentially unreliable) analysis in order to determine where to fold the stack. Alternatively or additionally, the registration feature can be used to indicate quality control information of the stack. For example, the registration feature can indicate whether a given portion of the stack is below a quality control standard and therefore the given portion of the stack should not be used or should be compensated when producing an energy storage device therefrom. This can allow reliable energy storage device production while reducing the need for quality control procedures during further processing of the stack, and therefore can allow efficient energy storage device production.

[0018] According to the third invention of the present invention, there is provided a stack for an energy storage device, the stack comprising a substrate, a first electrode layer, a second electrode layer, and an electrolyte layer between the first electrode layer and the second electrode layer; the stack defines a plurality of first grooves, each of which passes through the first electrode layer and the electrolyte layer; the stack further comprises at least one registration feature that is different from each of the plurality of first grooves. The registration feature can be used to indicate a folding point at or towards which the stack will be folded. This can allow efficient and reliable folding of the stack, and thus efficient production of energy storage devices. Alternatively or additionally, the registration feature can be used to indicate quality control information of the stack. This can allow reliable production of energy storage devices while reducing the need for quality control procedures during further processing of the stack, and thus can allow efficient production of energy storage devices.

[0019] In an example, each of the plurality of first grooves has an electrically insulating material deposited therein. The electrically insulating material may, for example, protect exposed edges within the first grooves from degradation during subsequent processing of the stack. Alternatively or additionally, the electrically insulating material may avoid direct electrical contact and thus short circuiting of electrode layers of the stack during laser ablation and / or during further processing of the stack.

[0020] According to a fourth aspect of the invention, there is provided a method comprising: folding a stack according to the third aspect at or towards a registration feature. Folding the stack at or towards an identified registration feature may allow efficient and reliable folding, for example without the need to calculate the number of first grooves between each fold as part of the folding. Folding the stack may allow efficient segmentation and production therefrom of relatively large capacity energy storage devices.

[0021] Other features and advantages of the present invention will become apparent from the following description, given by way of example only, which refers to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 is a schematic diagram showing a stack for an energy storage device according to an example;

[0023] Figure 2 is a diagram showing a method for processing according to an example Figure 1 A schematic diagram of a method of stacking to make an energy storage device;

[0024] Figure 3 is a flow chart illustrating a method of processing a stack according to an example;

[0025] Figure 4 is a schematic diagram showing one way of processing a stack according to a first example;

[0026] Figure 5 is a schematic diagram showing one way of processing a stack according to a second example;

[0027] Figure 6 It shows that according to Figure 5 A schematic diagram of the stack produced by the process; and

[0028] Figures 7 to 11 Schematically shows Figures 4 to 6 An exemplary manner of further processing the stack of any of the. DETAILED DESCRIPTION

[0029] Details of the methods, structures and devices according to the examples will become apparent with reference to the accompanying drawings, according to the examples. In this specification, many specific details of certain examples are set forth for the purpose of explanation. Reference to "example" or similar language in the specification means that a particular feature, structure or characteristic described in conjunction with the example is included in at least one example, but not necessarily in other examples. It should also be noted that certain examples are schematically described, in which certain features are omitted and / or must be simplified in order to facilitate explanation and understanding of the concepts underlying the examples.

[0030] Figure 1A stack 100 of layers for an energy storage device is shown. For example, Figure 1 The stack 100 may be used as part of a thin film energy storage device having a solid electrolyte.

[0031] The stack 100 includes a substrate 102, a cathode layer 104, an electrolyte layer 106, and an anode layer 108. Figure 1 In the example of FIG. 1 , the anode layer 108 is further away from the substrate 102 than the cathode layer 104, and the electrolyte layer 106 is located between the cathode layer 104 and the anode layer 108. The substrate 102 contacts the cathode layer 104 and supports the stack. Although in this example, the substrate 102 contacts the cathode layer 104, in other examples, there may be other layers (not shown) between the substrate 102 and the cathode layer 104.

[0032] In some examples, substrate 102 may be or may include nickel foil; however, it should be understood that any suitable metal may be used, such as aluminum, copper, or steel, or metallized materials including metallized plastics, such as aluminum on polyethylene terephthalate (PET).

[0033] The cathode layer 104 may serve as a positive current collecting layer. The cathode layer 104 may form a positive electrode layer (i.e., corresponding to the cathode during discharge of a battery of an energy storage device including the stack 100). The cathode layer 104 may include a material suitable for storing lithium ions through a stable chemical reaction, such as lithium cobalt oxide, lithium iron phosphate, or an alkali metal polysulfide salt.

[0034] Anode layer 108 may serve as a negative current collecting layer. Anode layer 108 may form a negative electrode layer (ie, corresponding to the anode during discharge of a battery including an energy storage device of stack 100). Anode layer 108 may include lithium metal, graphite, silicon, or indium tin oxide.

[0035] In some examples, anode layer 108 may include a negative current collector and a separate negative electrode layer (not shown). In these examples, the negative electrode layer may include lithium metal, graphite, silicon, or indium tin oxide, and / or the negative current collector may include nickel foil. However, it should be understood that any suitable metal may be used, such as aluminum, copper, or steel, or metallized materials including metallized plastics, such as aluminum on polyethylene terephthalate (PET).

[0036] The electrolyte layer 106 may include any suitable material that is ionically conductive but is also an electrical insulator, such as lithium phosphorus oxynitride (LiPON). The electrolyte layer 106 may be a solid layer and may be referred to as a fast ion conductor. A solid electrolyte layer may have a structure between a liquid electrolyte and a crystalline solid, where a liquid electrolyte, for example, lacks a regular structure and contains ions that can move freely. Crystalline materials, for example, have a regular structure with an ordered arrangement of atoms that may be arranged in a two-dimensional or three-dimensional lattice. The ions of a crystalline material are generally immobile and therefore may not be able to move freely throughout the material.

[0037] For example, stack 100 may be fabricated by depositing cathode layer 104 on substrate 102. Electrolyte layer 106 is subsequently deposited on cathode layer 104, and then anode layer 108 is deposited on electrolyte layer 106. Each layer of stack 100 may be deposited by flooding, which provides a simple and efficient way to produce highly uniform layers, although other deposition methods are possible.

[0038] Figure 1 The stack 100 may be processed to fabricate an energy storage device.

[0039] exist Figure 2 The schematic diagram shows the Figure 1 A general overview of an example of a process of stacking 100 .

[0040] exist Figure 2 In the example, stack 100 is processed to make an energy storage device. In this example, stack 100 is flexible, allowing it to be wound around roll 112, for example as part of a roll-to-roll manufacturing process (sometimes referred to as a reel-to-reel manufacturing process). Stack 100 can be gradually unwound from roll 112 and processed.

[0041] exist Figure 2 In an example of FIG. 1 , a groove may be formed in the stack 100 using a first laser 114. The first laser 114 is arranged to apply a laser beam 116 to the stack 100 to remove a portion of the stack 100 by laser ablation, thereby forming the groove.

[0042] After forming the grooves, an insulating material system 118 can be used to introduce an electrically insulating material into at least some of the grooves. The electrically insulating material can be considered to be non-conductive, so it can conduct a relatively small amount of current when subjected to an electric field. Generally, the current conducted by an electrically insulating material (sometimes referred to as an insulator) is less than that of a semiconductor material or a conductive material. However, there is still a small amount of current flowing through the electrically insulating material under the influence of the electric field, because even an insulator may include a small amount of charge carriers that carry the current. In the examples herein, the material can be considered to be electrically insulating, where the material is electrically insulating enough to perform the function of an insulator. For example, this function can be performed when the material fully insulates one element from another element to avoid a short circuit.

[0043] Reference Figure 2 After the electrical insulating material is introduced, the stack 110 is cut to form individual cells for an energy storage device. In some examples, hundreds or even thousands of cells may be cut from a roll of the stack 100, allowing multiple batteries to be manufactured in an efficient manner.

[0044] exist Figure 2 In the embodiment, the cutting operation is performed using a second laser 122, which is arranged to apply a laser beam 124 to the stack 100. Each cut may, for example, pass through the center of the insulating plug so that the plug is divided into two parts, each part forming a protective covering on the exposed surface including the edge to which it has been attached.

[0045] Although not in Figure 2 , but it will be appreciated that after the insulating material is introduced (or otherwise), the stack may be folded back on itself to form a z-fold structure having, for example, tens, possibly hundreds, or even thousands of layers, with each insulating plug aligned. The laser cutting process performed by the second laser 122 may then be used to cut the z-fold structure for each of the aligned plug groups in a single cutting operation.

[0046] After cutting the battery, electrical connectors can be arranged along opposite sides of the battery so that the first electrical connector on one side of the battery contacts (multiple) cathode layers 104, but is prevented from contacting other layers by an electrically insulating material. Similarly, the second electrical connector on the opposite side of the battery can be arranged to contact (multiple) anode layers 108, but is prevented from contacting other layers by an insulating material. Therefore, the insulating material can reduce the risk of short circuits between the anode and cathode layers 104, 108 and other layers in each battery. The first and second electrical connectors can, for example, include a metal material applied to the edge of the stack 110 (or to the edge of the intermediate structure 110) by sputtering. Therefore, the batteries can be effectively connected in parallel.

[0047] The foregoing description provides a general overview of an example of a stack 100 for an energy storage device, and examples of processes that may be applied to the stack 100 (e.g., for manufacturing an energy storage device). The following description provides examples of processes for processing a stack 200 (which may be similar to those described above). Figure 1 Exemplary methods and apparatus for stack 100 (the same or similar to the described stack) may provide improvements in processing efficiency of stack 200 and, therefore, for efficiently producing energy storage devices, such as batteries produced therefrom.

[0048] refer to Figure 3 , schematically illustrates a method of processing an energy storage device stack 200 according to an example.

[0049] In summary, the method includes obtaining a stack for an energy storage device in step 201, the stack including a substrate, a first electrode layer, a second electrode layer, and an electrolyte layer between the first electrode layer and the second electrode layer. The method further includes, in step 203, laser ablating the stack to form a plurality of first grooves in the stack, each of the plurality of first grooves passing through the first electrode layer and the electrolyte layer. The method further includes, in step 205, forming at least one registration feature in or on the stack that is different from each of the plurality of first grooves. In this example, the registration feature is used to indicate a folding point at or towards which the stack is to be folded.

[0050] As explained in more detail below, the method may allow efficient and reliable folding of a stack and thus, for example, efficient production of energy storage devices such as batteries.

[0051] In some examples, the registration features can be formed by methods other than laser ablation, such as by printing or scribing. For example, the registration features can be formed by depositing material, such as printing material, on the stack 200. As another example, the registration features can be formed by scribing or forming some other mark in the stack (e.g., without necessarily using laser ablation).

[0052] However, in the examples described below, forming the at least one registration feature includes laser ablating the stack to form the at least one registration feature. This may be effective because it may avoid providing separate devices for forming the first recess and the registration feature.

[0053] Reference now Figure 4 , schematically showing an energy storage device stack 200 (i.e., can be based on reference Figure 3 201 of the method described in the example), laser ablation 216a-216c, 218a, 218b is applied thereto to form a plurality of first grooves 210a-210c, 212a, 212b (according to reference Figure 3203 of the method described in the example of FIG. 1 ), and laser ablation 224 is applied thereto to form registration features 226 (according to reference Figure 2 205 of the method described above).

[0054] Stack 200 can be compared with reference Figure 1 The stack described is the same or similar. Figure 4 In the example shown, the energy storage device stack 200 includes a substrate layer 202, a cathode layer 204, an electrolyte layer 206, and an anode layer 202. These can be compared to the reference Figure 1 The layers of the stack 100 described are the same or similar. For example, the cathode layer 204 may include a cathode electrode and a cathode current collector ( Figure 4 ), and the anode layer 208 may include an anode electrode and an anode current collector ( Figure 3 (not shown). Figure 4 In the example shown, the electrolyte layer 206 is between the cathode layer 204 and the anode layer 208 , the cathode layer 204 is adjacent to the substrate layer 202 , the electrolyte layer 206 is adjacent to the cathode layer 204 , and the anode layer 208 is adjacent to the electrolyte layer 206 .

[0055] The cathode layer 204 and the anode layer 202 are reference Figure 3 Examples of first and second electrode layers are described.

[0056] like Figure 4 As shown, the energy storage device stack 200 has a plurality of first grooves 210a-210c, 212a, 212b formed therein. The plurality of first grooves 210a-210c, 212a, 212b are formed by laser ablation (in Figure 4 216a - 216c , 218a , 218b ) are formed in stack 200 .

[0057] As used herein, the term “groove” may refer to a channel, slot, or groove that may be continuous or discontinuous, and in some examples may be elongated, and may extend only partially through the layers 202 - 208 of the stack 200 .

[0058] As used herein, "laser ablation" may refer to the removal of material from the stack 200 using a laser-based process. Such removal of material may include any of a number of physical processes. For example, the removal of material may include (but is not limited to) melting, melt expulsion, vaporization (or sublimation), photon decomposition (single photon), photon decomposition (multi-photon), mechanical shock, thermomechanical shock, other shock-based treatments, surface plasma processing, and removal by evaporation (ablation). As explained in more detail below, the first grooves 210a-210c, 212a, 212b may be formed to partially divide the stack 200 into partial battery structures, but without (at this stage) completely separating those individual battery structures. This may allow further processing and handling of the stack 200 (e.g., folding, as described in more detail below), which may improve efficiency.

[0059] A first set 216a-216c of first grooves each extend into the stack from an opening on a first side 200a of the stack 200, and a second set 218a, 218b of first grooves each extend into the stack from an opening on a second side 200b of the stack 200 opposite the first side 200a.

[0060] Each of the first group 216a-216c and the second group 218a, 218b of first grooves is formed through the stacked first electrode layer and electrolyte layer 206. Specifically, the first group 216a-216c of first grooves is formed through the cathode layer 204 and the electrolyte layer 206 (i.e., for the first group 216a-216c of first grooves, Figure 3 The "first electrode layer" referred to in the figure is the cathode layer 204), and the second group 218a, 218b is formed through the anode layer 208 and the electrolyte layer 206 (i.e., for the second group 218a, 218b of the first grooves, Figure 3 The "first electrode layer" referred to in the figure is the anode layer 208).

[0061] Each of the first group 216a-216c of first grooves is formed through the substrate layer 202, the cathode layer 204 and the electrolyte layer 206, but not through the anode layer 208. In other words, each of the first group 216a-216c of first grooves is formed to expose the anode layer 208. The second group 218a, 218b of first grooves are formed through the anode layer 208, the electrolyte layer 206, the anode layer 204, respectively, but not through the substrate layer 202. In other words, each of the second group 218a, 218b of first grooves is formed to expose the substrate layer 202.

[0062] Each of the first grooves 210a-210c, 212a, 212b has a depth extending into the stack 200 in a direction substantially perpendicular to the planes of the layers 202-208; a width substantially perpendicular to the depth (in Figure 4 In the sense that each groove has a width and depth in the plane of the page), and a length extending in a direction substantially parallel to the plane of the layers 202-208 and substantially perpendicular to the width (i.e., in the plane of the page). Figure 4 Each of the first grooves 210a-210c, 212a, 212b is substantially parallel to each other in depth and length.

[0063] It should be noted that Figure 4 (similar to other figures) are schematic diagrams for illustration purposes only. For example, Figure 4 The sizes and relative spacing of the features shown in 200 (eg, layers 202 - 208 , first recesses 210 a - 210 c , 212 a , 212 b , registration features 226 ) are merely schematic and are used only to illustrate the example structures and processes described herein.

[0064] like Figure 4 As shown, the energy storage device stack 200 has a registration feature 226 formed therein. The registration feature 226 is used to indicate the folding point at or toward which the stack 200 will be folded. In this example, the registration feature 226 is formed by laser ablation (in Figure 4 2 (indicated by arrow 224 in the figure) is formed in the stack 200. The registration feature 226 is different from each of the plurality of first grooves 210a-210c, 212a, 212b. In this example, the registration feature 226 is also a groove, but is different from each first groove in that the registration feature 226 only partially extends from the second side 200b of the stack into the anode layer 208 (i.e., its depth is less than the depth of each first groove 210a-210c, 212a, 212b) and is also wider than each first groove 210a-210c, 212a, 212b.

[0065] As described above, the registration feature 226 is used to indicate a fold point at or toward which the stack 200 is to be folded. As explained in more detail below, folding the stack 200 can allow the stack 200 to be efficiently separated into battery cells. Forming the registration feature 226 (different from the first plurality of grooves) can allow the fold points in the stack 200 to be efficiently and reliably identified during further processing of the stack. For example, the stack 200 having the first grooves 210a-210c, 212a, 212b and the registration feature 226 formed therein can be processed by a folder (described in more detail below), and the registration feature 226 can provide a means by which the folder can effectively register (i.e., identify and / or align) the points at which the stack 200 is to be folded, for example, without having to count the number of first grooves between each fold.

[0066] It will be understood that Figure 4The illustrated registration features 226 are examples, and other forms of registration features 226 for indicating a fold point at or toward which the stack 200 is to be folded may be used.

[0067] In some examples, the depth of the registration feature 226 can be less than the depth of each of the first grooves 210a-210c, 212a, 212b. For example, the registration feature can be a shallow cut or mark 226 that does not penetrate one or more outer layers 208, 202 of the stack. For example, in this example, the shallow cut or mark 226 only partially penetrates the outer layers 208, 202 of the stack 200. In some examples, the shallow cut or mark 226 can be substantially the same as the plurality of first grooves, except that the depth of the mark 226 is less than the depth of each first groove. The registration feature 226 having a depth less than the depth of each first groove 210a-210c, 212a, 212b can allow the speed and therefore efficiency of the processing of the stack 200 to be improved. For example, it may take less time to form a relatively shallow registration feature 226 by laser ablation than if another first groove is formed instead. It may not be necessary to form the first groove at the point where the stack 200 is to be folded, because, as described in more detail below, in any case, the portion of the stack 200 at the fold point can be discarded as scrap. Therefore, by forming shallow registration features 226, as described, the rate of laser ablation of the stack 200 can be increased without adversely affecting the cells singulated therefrom.

[0068] In some examples, shallow cutouts or markings 226 can have a particular shape or pattern, such as a predetermined shape or pattern, e.g., different from the shapes or patterns of other features of stack 200. This can allow registration features 226 to be effectively and reliably recognized by a recognition device, such as a camera of a folder (described in more detail below).

[0069] It will be appreciated that in some examples, registration feature 226 may not be precisely at the point at which stack 200 will be folded. In some examples, registration feature 226 may be oriented toward such a point and still effectively indicate a folding point. For example, a folder (not shown) may be configured to fold the stack at some predetermined distance from registration feature 226 or at some predetermined time after identifying registration feature 226 (e.g., if stack 200 is moving relative to the folder).

[0070] In some examples, the registration feature 226 can be a groove in the stack that is wider and / or deeper and / or has a different shape than each of the plurality of first grooves 210a-210c, 212a, 212b. For example, the registration feature groove 226 can have a width and / or depth and / or shape that facilitates the stack 200 to fold at the registration feature groove 226. For example, the registration feature groove 226 can have a cross-sectional shape different from each first groove in a plane perpendicular to its length and the layers of the stack 200. For example, the registration feature groove 226 can be tapered. For example, the width of the registration feature groove 226 can increase as the proximity to the outer surface 200a, 200b of the stack increases. For example, this can promote the folding of the stack 200 at the registration feature groove 226 by promoting a crisp fold. Alternatively or additionally, the registration feature groove 226 can be deeper and / or wider than the first grooves 210a-210c, 212a, 212b. This may also facilitate folding of the stack 200 at the registration feature recess 226. Making the registration feature recess 226 wider than the first recess may also facilitate identification of the registration feature 226, such as by a folding machine (described in more detail below).

[0071] In some examples, the registration feature 226 may include a perforation in the stack 200. For example, the registration feature 226 may include a series of spaced apart slits (not shown) in the stack 200, which may, for example, extend parallel to the length of the first grooves 210a-210c, 212a, 212b. The perforations may weaken the stack 200, and thus may facilitate folding of the stack along the perforations. For example, the slits of the perforations may extend through the entire depth of the stack 200, i.e., through each of the substrate layer 202, the cathode layer 204, the electrolyte layer 206, and the anode layer 208, thereby effectively forming a hole through the stack. In this way, the stack 200 may be significantly weakened along the perforations to facilitate folding without being completely segmented, which may allow (continued) processing of the stack 200. In addition, forming a series of slits (like perforations) may allow for increased speed, and therefore efficiency, of laser ablation of the stack 200, because less laser ablation may be spent to form the slits (e.g., less material needs to be ablated) than the corresponding grooves.

[0072] In some examples, conveniently, according to reference Figure 3 The method described in step 203 is used to form a stack of a plurality of first grooves 210a-210c by laser ablation, 212a, 212b and according to reference Figure 3 The laser ablation of stack 200 to form registration features 226 of step 205 of the described method uses laser light from a common laser source 220 .

[0073] For example, in Figure 4In the example schematically shown in FIG. 2 , the laser ablations 218 , 218 b forming the second set of first grooves 212 a , 212 b and the laser ablations 224 forming the registration features 226 both use laser light from a common laser source 220 .

[0074] In some examples, laser source 220 may include, for example, two or more light sources (not shown), each of which may produce light (e.g., laser light) that may be mixed to produce a single laser beam. In these examples, it will be understood that a system of two or more light sources and a combined device thereof may be referred to as a single "laser source 220".

[0075] In some examples, the method may include moving in the first direction of travel 236 (i.e., in Figure 4 Move the stack 200 from right to left. Figure 4 As shown, each of the plurality of first grooves 216, 218 formed in the stack 200 is elongated in a direction substantially perpendicular to the first direction 236 (i.e., the first direction 236 is substantially perpendicular to the length of each of the plurality of first grooves 216, 218). For example, the stack 200 can be formed in a roll-to-roll type process (e.g., as described in reference Figure 2 The first direction of travel 236 may be between the two reels ( Figure 4 Not shown; see for example Figure 6 The stack 200 may be moved simultaneously or intermittently with the laser ablation forming the first grooves 218 , 216 or the at least one registration feature 226 .

[0076] In some examples, stack 200 can be moved along first direction 236 so that successive portions of the stack are aligned with the ablation beam of laser source 220. For example, stack 200 can first be positioned relative to laser source 200 (not shown) so that laser ablation beam 218a forms first first groove 212a of first groove. The stack can then be moved along direction of travel 236 so that the stack is positioned relative to laser source 220 of laser ablation beam 224 (not shown) to form registration feature 226. Then, stack 200 can be moved again along direction of travel 236 so that laser source 220 is positioned relative to stack 200 (i.e., as Figure 4 As shown) is used for the ablation beam 218b to form a second first groove 212b of the first groove.

[0077] In some examples, the laser source 220 or the ablation beam generated thereby may be moved to be properly positioned relative to the stack 200 to form the first grooves 212a , 212b and the registration features 226 .

[0078] In some examples, the laser source 220 can generate a source beam that is split or otherwise manipulated to provide two or more of the ablation beams 218a , 224 , 218b for forming the first grooves 212a , 212b and the registration feature 226 .

[0079] In an alternative example, the stack 200 moves along a second, different direction of travel 238 (i.e., Figure 4 In the sense of moving in or out of the page). Each of the plurality of first grooves 216, 218 formed in the stack can be elongated in a direction substantially parallel to the second direction 238 (i.e., the second direction 238 can be substantially parallel to the length of each of the plurality of first grooves 216, 218). For example, the method can include moving the stack 200 in the second direction 238 simultaneously or intermittently with laser ablation forming the first grooves 218, 216 or at least one registration feature 226. For example, the stack 200 can be moved in the second direction 238 such that each first groove 212a, 212b, etc. (and, for example, the registration feature 226) can be gradually formed in the length direction by movement of the stack 200 relative to the laser 200. Again, the stack 200 can be moved in a roll-to-roll type process, wherein the stack 200 is rolled off a first reel for laser ablation and wound onto a second reel once the laser ablation has been performed. The second travel direction 236 can be between the two reels ( Figure 4 is not shown; but see for example Figure 7 ). In this example, in order to form the first grooves 212a, 212b and the registration features 226 by laser ablation using a common laser source 220, multiple laser beams can be distributed over the stack 200. For example, the laser source 220 can produce a source beam that is split to provide ablation beams 218a, 224, 218 distributed over the entire stack 200. Additionally or alternatively, in some examples, multiple laser sources (not shown) can be provided, one for forming each first groove 212a, 212b. The laser system 223 can be set as a fixture, and the stack 200 moves relative to the fixture to form each of the first grooves 212a, 212b and the registration features 226. This can provide effective, substantially continuous and / or reliable laser ablation. In other examples, one or more laser sources 220 or beams generated thereby can be arranged to move across the stack 200 (i.e., in a direction perpendicular to the second travel direction 238 of the stack), for example. For example, this may provide that fewer laser beams and / or laser sources may be used, or a lower powered laser source 220, which may provide a cost effective arrangement.

[0080] In any case, in examples where laser ablation to form the first grooves 212a, 212b and the registration feature 226 uses a common laser source 220, efficient and cost-effective ablation can be provided, for example, compared to using separate laser sources to form the first grooves 212a, 212b and the registration feature 226.

[0081] Laser ablation performed on different sides 200a, 200b of the stack may use laser light from different laser sources (not shown) or the same laser source 220. Laser light from the same laser source 220 may be provided on different sides 200a, 200b of the stack 200, for example, by appropriately splitting and directing the source beam of the laser source 220. Again, laser ablation using a common laser source 220 may allow for efficient and cost-effective ablation.

[0082] In some examples, one alignment feature 226 may be formed in each given number of adjacent grooves in the plurality of first grooves 216a-216c, 218a, 218b. For example, a plurality of alignment features 226 may be formed, wherein one alignment feature 226 is formed after or between every N first grooves, for example, where N is a positive integer in the range of 2-1000. It should be understood that any predetermined number may be used. Forming one alignment feature 226 in each given number of adjacent first grooves in the plurality of first grooves 216a-216c, 218a, 218b may allow subsequent folding (described in more detail below) stacked at or toward the alignment feature 226 will result in layers of uniform length and / or layers with correct battery registration, which may allow for more efficient battery segmentation (described in more detail below).

[0083] In some examples, a given number of adjacent first grooves in a plurality of first grooves 216a-216c, 218a, 218b between consecutive registration features 226 may be determined based on quality control information. For example, the formation location of the registration features in or on the stack 200 may be determined based on information related to whether a portion of the stack 200 is below a quality control standard. An appropriate stack analysis may be used to determine whether a portion of the stack is below a quality control standard. For example, the number of grooves between the registration features may be determined based on information related to whether a portion of the stack 200 is below a quality control standard, and therefore, more first grooves should be included between the registration features 226. This may allow consistent battery production while reducing the need for quality control procedures in subsequent processing of the stack 200, and may therefore allow for a more efficient process.

[0084] In some examples, the plurality of first grooves 216a-216c, 218a, 218b can be formed sequentially (i.e., one after the other), and the registration feature 226 can be formed after a given number of consecutive grooves in the plurality of first grooves 216a-216c, 218a, 218b. For example, in an example where the stack 200 is moved along a first direction 236 perpendicular to the length of the first grooves 216a-216c, 218a, 218b, laser ablation to form the registration feature 226 can be performed after laser ablation to form a given number of first grooves (e.g., 30) (or otherwise).

[0085] In some examples, properties of the laser ablation used to form the plurality of first recesses 210 a - 210 c , 212 a , 212 b can be modified to provide laser ablation used to form the at least one registration feature 226 .

[0086] For example, a property of laser ablation that can be modified can be the speed at which the stack 200 moves relative to the laser source 220 and / or the ablation beam generated thereby. For example, the ablation beam can move at a first speed relative to the stack 200 to produce each of the plurality of first grooves 210a-210c, 212a, 212b, and can move at a second, different speed relative to the stack 200 to produce the registration feature 226. For example, the first speed can be faster than the second speed, such that the registration feature 226 can be formed as a deeper groove than each of the plurality of first grooves 210a-210c, 212a, 212b. As another example, the first speed can be slower than the second speed, such that the registration feature 226 can take the form of a shallow cut, mark, or perforation.

[0087] As another example, the modified properties of laser ablation can be properties of the laser used in ablation. For example, the method can include modifying the properties of the first laser 218a, 218b used for laser ablation to form the plurality of first grooves 210a-210c, 212a, 212b to provide a second laser 224 used for laser ablation to form at least one registration feature 226. For example, ablation light for forming the plurality of first grooves 210a-210c, 212a, 212b and the registration feature 226 can be provided from a common laser source 220, and the properties of the laser from the common laser source 220 can be modified to provide different forms of the first grooves 210a-210c, 212a, 212b and the registration feature 226.

[0088] In other examples, the modified properties of the laser may include (but are not limited to) one or more of the shape of the first laser, the intensity of the first laser, the power of the first laser, the focal position of the first laser, and the repetition frequency of the laser.

[0089] Modifying the shape of the laser light (eg, the shape of a cross section of the laser beam in a plane perpendicular to the beam axis) may, for example, allow for the formation of registration features 226 having a predetermined shape or pattern, eg, recognizable by a folding machine.

[0090] Modifying the intensity (e.g., power per unit area) of the first laser can allow, for example, the formation of a registration feature 226 that has a depth that is different from the depth of each first groove 212a, 212b. For example, forming the registration feature 226 using a lower intensity laser can produce a registration feature 226 that is shallower than each first groove 212a, 212b. Conversely, forming the registration feature 226 using a higher intensity laser can produce a registration feature 226 that is deeper than the depth of each first groove 212a, 212b. Changing the intensity can allow the registration feature 226 to be formed to be different from each of the plurality of first grooves 212a, 212b, but without having to change the speed at which the ablation beam travels relative to the stack, which can allow for more efficient processing. The intensity of the laser can be changed by changing the power of the laser and / or the beam size or focus of the laser. Modifying the power of the laser can allow the intensity of the laser to be modified without having to modify the beam size or focus, which can allow for consistent laser ablation beam positioning.

[0091] Modifying the repetition rate of the laser (e.g., where the laser source 220 is a pulsed laser source 220) can allow the degree of ablation achieved by the ablation beam in a given time to be modified. For example, this can allow the depth and / or pattern of the registration features 226 to be different from each of the first grooves 212a, 212b, for example, for a given speed of movement of the stack 200 relative to the ablation beam.

[0092] In some examples, the method may include providing a substance 240 in the area of ​​each of the plurality of first recesses 210a, 212a, 210b.

[0093] For example, refer to Figure 5 , again schematically showing a stack 200, including a substrate layer 202, a cathode layer 204, an electrolyte layer 206, and an anode layer 208. Similar to Figure 4 In the arrangement, laser ablation 216a, 216b, 218a is applied to form a plurality of first grooves 210a, 210b, 212a respectively (according to reference Figure 3 203 of the method described above), applying laser ablation 224 to form registration features 226 (according to reference Figure 3 205 of the method described above).

[0094] like Figure 5 As shown, laser ablation to form first grooves 210a, 212a, 216b exposes at least the surface, such as the edge, of the electrode layers 204, 208 of the stack 200. Figure 4 As shown, taking the first first groove 210a of the first grooves formed from the first side 200a of the stack 200 as an example, the laser ablation for forming the first first groove 210a of the first grooves exposes the edge of the substrate layer 202a, the edge 204b of the cathode layer 204, and the edge 206a of the electrolyte layer 206. Similarly, for the second groove 212a formed from the second side 200b of the stack, the laser ablation exposes the edge 202a of the anode layer 208, the edge of the electrolyte layer 206, and the edge 204a of the cathode layer 204.

[0095] As already mentioned, in some examples, the method may include providing a substance 240 in the region of each of the plurality of first recesses 210a, 212a, 210b.

[0096] In some examples, the substance includes an inert gas. The inert gas can be substantially dry. The inert gas can replace oxygen and / or moisture in the laser ablation area. During the laser ablation to form the first grooves 210a, 212a, 210b, this can reduce the reaction tendency of the layers 202 to 208 at the exposed surfaces (e.g., edges 202a, 204a, 206a, 208a). The process can maintain the purity of the layers, which in turn can provide more reliable operation of the battery produced from the stack 200.

[0097] In some examples, the substance 240 includes a monomer. The monomer can be suspended in a gas, such as an inert gas. In some examples, the method can include providing the monomer suspended in the inert gas in the region of at least one of the first recesses 210a, 212a, 210b during laser ablation to form the first recess, so that the monomer polymerizes onto the exposed surface, such as the edge 204a, 208a of the first electrode layer 204, 208. For example, the monomer can be polymerized by the laser ablation itself, i.e., in a photoinduced polymerization.

[0098] Figure 6 Schematic diagram showing the laser ablation process Figure 5 The stack is 200. Figure 6 As shown, a polymerized monomer 246 (hereinafter referred to as polymer 246) may be formed on each surface, for example, by edges 202a, 204a, 206a, 208a exposed by laser ablation to form first grooves 210a, 212a, 210b. Figure 5 As shown, polymer 246 may substantially fill each of the plurality of first recesses 210a, 212a, 210b. Polymer 246 formed on exposed edges 202a, 204a, 206a, 208a may protect the exposed edges from degradation, such as during subsequent processing of stack 200, for example.

[0099] In some examples, the polymer 246 can be an electrically insulating material or dielectric. For example, the polymer 246 can be formed on the exposed surface, such as the edges 202a, 204a, 206a, 208a, so as to provide electrical insulation between the exposed edges 204a, 208a of the first electrode 202, 206 (i.e., one of the cathode layer 204 and the anode layer 208) and the exposed edges 204a, 208a of the second electrode 202, 206 (i.e., the other of the cathode layer 204 and the anode layer 208). This can avoid direct electrical contact and thus short circuiting of the charged anode layer 206 with the cathode layer 202 during laser ablation and / or further processing of the stack 200 (e.g., folding described in more detail below). This can improve the consistency of stack processing and / or can improve the safety of processing. As described in more detail below, providing insulating material in the first groove at this stage may also reduce the need to provide insulation on the folded stack edge at a later stage of further processing of the stack 200 , which in turn may allow for more efficient further processing of the stack 200 .

[0100] In any case, for example, using a laser beam for laser ablation to form the plurality of first grooves 210a, 212a, 210b to polymerize the monomer onto the exposed edges 202a, 204a, 206a, 208a can, for example, reduce the need to provide a separate deposition system to cover (e.g., electrically insulate) the exposed edges or avoid using a separate deposition system to cover (e.g., electrically insulate) the exposed edges. Additionally or alternatively, such a method can reduce the need to perform covering the exposed edges at different times, and thus can provide more efficient processing of the stack 200.

[0101] In some examples (not shown), substance 240 may be provided in the region of registration feature 226 during laser ablation to form registration feature 226 (thereby forming polymerized monomer 246 therein), e.g., to provide similar advantages as mentioned with respect to first recesses. However, in other examples (as shown), substance 240 may not be provided in the region of registration feature 226 and / or registration feature 226 may not have polymerized monomer formed thereon or therein (e.g., the laser ablation used to form registration feature 226 may be such that polymerization of monomer is not induced). In some examples, registration feature 226 may differ from each of the plurality of first recesses 210a, 210b, 212a, e.g., only in that registration feature 226 does not have polymerized monomer 246 formed therein, whereas each of the plurality of first recesses 210a, 210b, 212a does have polymerized monomer 246 formed therein.

[0102] Therefore, reference Figures 3 to 6The (intermediate) product of the described method can be a stack 200, which includes a substrate 202, a first electrode layer 204 / 208, a second electrode layer 204 / 208, and an electrolyte layer 206 between the first electrode layer 204 / 208 and the second electrode layer 204 / 208. The stack 200 defines a plurality of first grooves 210a, 210b, 212a, each of which passes through the first electrode layer 204 / 208 and the electrolyte layer 206, and also includes at least one alignment feature 226 for indicating a folding point at or toward which the stack is to be folded. Each of the plurality of first grooves 210a, 210b, 212a may have an insulating material deposited therein. In some examples (e.g., as described in more detail below), the stack 200 may be folded at or toward the alignment feature 226.

[0103] The equipment can be arranged (see, for example, Figure 4 Device 225 in to perform Figures 1 to 5 In some examples, refer again to Figure 4 , the device may include a laser system 223 , which may include a laser source 220 , a modifier element 22 and a control battery 221 .

[0104] The laser system 223 can be arranged to, in use: laser ablate the stack 200 to form a plurality of first grooves 210a, 210b, 212a in the stack 200, each of the plurality of first grooves passing through the first electrode layer 204 / 208 and the electrolyte layer 206. In some examples, the device 225 can be arranged to form at least one alignment feature 226 in or on the stack that is different from each of the plurality of first grooves 210a, 210b, 212a, for indicating a folding point at or toward which the stack is to be folded. For example, in some examples, the device 225 can include a mark forming device, such as a cutting device (which may not be a laser-based device) to form the alignment mark. However, as has been described, in some examples, the laser system 223 can be arranged to laser ablate the stack 200 to form at least one alignment feature 226 that is different from each of the plurality of first grooves 210a, 210b, 212a, for indicating a folding point at or toward which the stack is to be folded.

[0105] The laser system 223 may be arranged to laser ablate the stack 200 using laser light from the first laser source 220 to form the plurality of first grooves 210 a , 210 b , 212 a , and to laser ablate the stack 200 to form at least one registration feature 226 .

[0106] In these examples, the device 225 may include a modifier (e.g., depicted as element 222) arranged to modify properties of the laser ablation forming the plurality of first grooves 210a, 210b, 212a to provide laser ablation forming at least one registration feature 226. The control cell 221 may be arranged to control the modification of the laser ablation by such a modifier 222.

[0107] In some examples, the modifier can be arranged to modify the speed at which the stack 200 moves relative to the laser system 223 (not shown). For example, the device 225 can include a device (not shown) for moving the stack 200 (e.g., a motor for a reel in a roll-to-roll type process as described) and / or a device for moving the laser source 220 or its ablation beam (e.g., a motor (not shown) for a movable ablation head). In these examples, the control battery 210 can be arranged to control the speed at which the stack 200 moves. For example, the control battery 221 can be arranged to control the speed at which the device (not shown) moves the stack 200 and / or the laser system 223.

[0108] In some examples, a modifier (e.g., element 222) may be arranged to modify properties of a first laser used for laser ablation to form the plurality of first grooves 210a, 210b, 212a to provide a second laser used for laser ablation to form the at least one registration feature 226. In these examples, the control battery 221 may be arranged to control the modifier to modify properties of the laser.

[0109] For example, the modifier may be or include a component (not shown) of the laser source 200 itself, e.g., that changes the manner in which the laser light is generated by the laser source 200. For example, the modifier may modify the intensity, power, and / or repetition rate of the laser light generated by the laser source 200. In these examples, the control cell 221 may be communicatively connected to the laser source 220 in order to control the components of the laser source 220. Changing the properties of the laser light generated from the laser source 200 itself may, for example, allow the ablation beam to be changed without changing the laser path, which may allow for consistent ablation.

[0110] In some examples, the modifier may be or may include a modifier element 222 that modifies the properties of the laser beam generated by the laser source 200. For example, the modifier element 222 may include a mask. For example, the mask may change the shape and / or intensity of the laser beam. As another example, the modifier element 22 may include one or more optical elements. For example, one such optical element may be or may include a neutral density filter for reducing the power of the laser and thus reducing its intensity. As another example, the optical element may include a lens. For example, the lens may be configurable to modify the focal position of the laser beam. In these examples, the control battery 210 may be arranged to control the modifier element 222 to modify the properties of the laser beam. For example, the control battery may control the movement of the modifier element to achieve control of the modification of the laser beam from the laser source 220. By modifying the laser light using the modifier element 222 in the optical path of the laser beam, which in turn is generated by the laser source 200, flexible modification may be allowed as well as the generation of the laser light by the laser source 220 without changing it, which in turn may allow for the generation of consistent laser light.

[0111] In some examples, the device 225 may include a substance source (not shown) for introducing a substance 240 (e.g., an inert gas, a monomer, and / or a monomer suspended in an inert gas) into, for example, selectively into the region of the first recesses 210a, 210b, 212a, as described above with reference to Figure 6 Described by example.

[0112] Figures 7 to 11 Schematically shown by reference Figures 3 to 6 Exemplary further processing of stack 200 formed by method and / or apparatus 225 is described.

[0113] In some examples, further processing may include identifying registration feature 226 , and folding stack 200 at or toward registration feature 226 .

[0114] A folder (not shown) may be arranged to identify the registration feature 226 and to fold the stack 200 at or towards the registration feature(s) 226 .

[0115] In some examples, a folding machine (not shown) may be part of the apparatus 225 described above. Alternatively, the folding machine may be separate from the apparatus 225 described above. The folding machine (not shown) may include a device (not shown) for identifying or distinguishing the registration feature 226. For example, the identification device may include a camera or other sensor arranged to identify a registration feature 226 of the stack 200 that is different from each of the plurality of first grooves 210a, 210b, 212a, etc. The folding machine being arranged to fold the stack 200 at or towards the identified registration mark may allow the folding machine to reliably and efficiently fold the stack 200, for example without having to count the number of first grooves between each fold.

[0116] In some examples, further processing of the stack 200 may include cutting the stack 200 into one or more strips 254 , 260 prior to folding the stack 200 at or toward the registration feature 226 .

[0117] For example, now specifically refer to Figure 7 , schematically shows an example of further processing of the stack 200 in a roll-to-roll type process. Figure 7 As shown, the stack 200 is provided by the reel 252 so as to travel in the first direction 236. A plurality of first grooves 218 and registration features 226 can be formed on / in the stack 200, for example, as shown in reference Figures 3 to 6 Described. Figure 7 In the example shown, the plurality of first grooves 218 and the registration features 226 (in this example in the form of grooves 226 that are parallel to the first grooves 152 ) are elongated in a direction perpendicular to the first direction of travel 236 .

[0118] like Figure 7 As schematically shown in FIG. 1 , the stack 200 (in which the first groove 218 and the registration feature 226 are formed) can be cut into a plurality of strips 254 (in Figure 7 The strips 254 may be formed, for example, by laser cutting (not shown) the stack 200 in a direction parallel to the first direction of travel 236. Each strip 254 is elongated in a direction perpendicular to the length of the first groove 218. Each strip 254 may then be folded at or toward the registration feature 226 (e.g., during a folding process and / or by a folding machine as described above) to produce a folded stack 256 (i.e., a stack folded at or toward the registration mark 226). It should be understood that although in Figure 7 Only one fold is shown in FIG. 1 , but in other examples, there may be many folds, such that the folded stack 256 includes many layers of stacks, such as tens or hundreds of layers (see also FIG. 1 ). Fig. 9 ).

[0119] As another example, now refer to Figure 8 , schematically shows another example of further processing of the stack 200. Figure 8 As shown, the stack 200 is provided by the reel 258 so as to travel in the second direction 238. A plurality of first grooves 218 and registration features 226 can be formed on / in the stack 200, for example, as shown in reference Figures 3 to 6 Described. Figure 8 In the example shown, the plurality of first grooves 218 and registration features 226 (in this example in the form of grooves 226 that are parallel to the first grooves 152) are elongated in a direction perpendicular to the first direction of travel 238. As described, forming the first grooves 218 and / or registration features 226 in this orientation can allow the laser source and / or ablation beam generated thereby to be provided by a static laser system relative to which the stack 200 can be moved, e.g., to form the first grooves 218 and / or registration features 226 in a substantially continuous process, which can be effective.

[0120] like Figure 8 As schematically shown in FIG. 1 , the stack 200 (in which the first groove 218 and the registration feature 226 are formed) can be cut into a plurality of strips 260 (in Figure 8 The strips 260 may be formed, for example, by laser cutting (not shown) the stack 200 in a direction perpendicular to the second direction of travel 238. Again, each strip 260 is elongated in a direction perpendicular to the plane of the first groove 218. Each strip 260 may then be folded at or toward the registration feature 226 (e.g., during a folding process and / or by a folding machine as described above) to produce a folded stack 262 (i.e., a stack folded at or toward the registration mark 226). It should be understood that although in Figure 8 Only one fold is shown in FIG. 1 , but in other examples, there may be many folds, so that the folded stack 262 includes many layers of stacks, such as tens or hundreds of layers (see also FIG. 1 ). Fig. 9 ).

[0121] It will be appreciated that in some examples, Figure 7 The folded stack 256 can be connected with Figure 8 The folded stack 262 is substantially identical (e.g., indistinguishable). However, according to Figure 8 , cutting of the stack 200 substantially parallel to the first direction of travel 236 may allow for parallel processing of each of the strips 254 produced and may therefore allow for an efficient production process.

[0122] A cutting device (not shown) may be provided that is arranged to cut the stack 200 to form the strips 254, 260. The cutting device (not shown) may form part of the described device 225 and / or the folder (not shown), or may be a separate device. The cutting device (not shown) may include a laser cutter (not shown) that is arranged to cut the stack into the strips 254, 260.

[0123] Reference now Fig. 9 , shows an example of a folded stack 256, 262. The folded stack 256, 262 can be, for example, referred to as Figure 7 and 8 The process described describes the folding process and / or folding machine to produce. Fig. 9 As shown, the folded stack 256, 262 has four stack layers 200a-200d (each stack layer includes a Figures 3 to 6 The stack 200 formed by the method described above is folded in a "z-fold" arrangement. In other words, the second stacked layer 200b is folded back on the first stacked layer 200a at the first registration feature 226a, so that the planes defined by the layers of the first stacked layer 200a and the second stacked layer 200b are substantially parallel to each other. Similarly, the third stacked layer 200c is folded back on the second stacked layer 200b at the second registration feature 226b, and the fourth stacked layer 200d is folded back on the third stacked layer 200c at the third registration feature 226c. Since the registration features 226a-226c are equally spaced along the length of the bands 256, 262, each stacked layer 200a-200d has the same length, so that the stacked layers 200a-200d are registered or aligned with each other. The portion 264 of the stacked layers 200a-200d at the fold (i.e., the central portion of the stack 256 away from the fold) can be removed and / or treated as waste.

[0124] In some examples, further processing may include segmenting the folded stack 256 , 262 into cells 270 a , 270 b .

[0125] For example, refer to Fig.10 , showing the central portion of the folded stack 256, 262 in more detail. Fig.10 As shown, each stacked layer 200a-200d is aligned with each other, that is, the first grooves of one stacked layer 200a (e.g., each filled with insulating polymer material 246) are aligned with the corresponding grooves of the adjacent stacked layer 200b (i.e., in Fig.10Each stack layer includes a substrate layer 202, a cathode layer 204, an electrolyte layer 206, and an anode layer 202. It should be noted that since the second stack layer 200b is folded back onto the first stack layer 200a, the second stack layer 200b is inverted compared to the first stack layer 200a, and similarly, the third stack layer 200c is inverted compared to the second stack layer 200b, and the fourth stack layer 200d is inverted compared to the third stack layer 200c.

[0126] like Fig.10 As schematically shown in , further processing may include battery segmentation, i.e., segmenting the folded stack into batteries of energy storage devices 270a, 270b. In this example, battery segmentation includes laser ablation 266a-266c to form cuts 268a-268c through all first to fourth stacked layers 200a-200d at each location where the first groove is aligned. It should be understood that in the example where the first groove is filled with polymer 246, the cuts 268a-268c include cuts through polymer 246. The cuts 268a-268c segment the folded stack into batteries 270a, 270b.

[0127] A singulation device (not shown) may be provided, for example, as described herein, which is arranged to singulate the folded stack 256, 252 into cells 270a, 270b. The singulation device (not shown) may be part of the device 225, the folder (not shown) and / or the cutting device (not shown), or may be a separate device. The singulation device (not shown) may include a laser cutter for cutting through the stack layers to form cells 227a, 227b, as described.

[0128] An example of a divided battery 270b is as follows Fig.11 shown.

[0129] Battery 270b includes the following layers in the following order (in Fig.11 In the sense from bottom to top): first substrate layer 202a, first cathode layer 204a, first electrolyte layer 206a, first anode layer 208a, second anode layer 208b, second electrolyte layer 206b, second cathode layer 204b, second substrate 202b, third substrate 202c, third cathode layer 204c, third electrolyte layer 206c, third anode layer 208c, fourth anode layer 208d, fourth electrolyte layer 206d, fourth cathode layer 204d and fourth substrate 202d.

[0130] As described, the formation of the first groove in the stack 200 and the insulating material 246 disposed in the first groove, the folding and segmentation described provide for the segmented battery 270b to be formed only on the first side 72 of the battery (at Fig.10The surfaces including the anode layers 208a-208d are exposed on the first side 272 (in the sense of the right side), with all other layers being insulated by the polymer 246 on the first side 272. Moreover, only the surfaces including the substrate layers 202a-202d are exposed on the second, opposite side 274 of the battery 270b, with all other layers being insulated by the polymer 246 on the second side 272. As described, the substrate layers 202a-202d can include a conductive material, such as nickel.

[0131] A first side 272 of the battery 270b can be coated with a first conductive material (not shown) to electrically connect all of the anode layers 208a-208d together, and a second side 274 of the battery 270b can be coated with a second conductive material (not shown) to electrically connect all of the substrate layers 202a-202d (and therefore all of the cathode layers 204a-204d) together. For example, a sputtered metal layer can be applied to both sides 272, 274 of the battery 270b. In this way, for example, the first conductive material can provide contact for a first terminal of the battery 270b (e.g., a positive terminal of the battery 270b), and the second conductive material can provide contact for a second terminal of the battery 270b (e.g., a negative terminal of the battery 270b). In other words, in effect, the four sub-cells of the battery 270b (i.e., one for each of the four stacked layers 200a-200d) are connected in parallel. The positive terminal and the negative terminal can be electrically connected across a load to power the load. Providing a cell 270b that includes a group of sub-cells (ie, one for each of the four stacked layers 200a-200d) may provide a useful battery cell, for example, to provide a relatively high discharge rate, which may be useful in certain applications.

[0132] Thus, it will be appreciated that the registration features 226 formed on / in the stack 200 as described herein can provide for reliable and efficient folding of the stack, which in turn can provide for reliable and efficient production of, for example, energy storage devices such as batteries 270b.

[0133] The above examples should be understood as illustrative examples of the present invention. It should be understood that any feature described with respect to any one example can be used alone or in combination with other features described, and can also be used in combination with one or more features of any other example or any combination of other examples. In addition, without departing from the scope of the present invention defined in the appended claims, equivalents and modifications not described above may also be adopted.

Claims

1. A method of processing a stack for an energy storage device, include: obtaining a stack for an energy storage device, the stack comprising a substrate, a first electrode layer, a second electrode layer, and an electrolyte layer between the first electrode layer and the second electrode layer; laser ablating the stack to form a plurality of first grooves in the stack, each of the plurality of first grooves passing through the first electrode layer and the electrolyte layer; forming at least one registration feature in or on the stack that is different from each of the plurality of first recesses; identifying registration features; and folding the stack at or towards the identified registration features, Wherein, every given number of adjacent first grooves in the plurality of first grooves forms one alignment feature.

2. The method according to claim 1, in, Forming at least one registration feature includes laser ablating the stack to form the at least one registration feature.

3. The method according to claim 2, in, The laser ablation to form the plurality of first grooves and the laser ablation to form the at least one registration feature use laser light from a common laser source.

4. The method according to claim 2 or 3, in, The method includes varying a property of laser ablation used to form the plurality of first grooves to provide laser ablation used to form the at least one registration feature.

5. The method according to claim 4, in, Changing the properties of the laser ablation includes changing the properties of a first laser used for laser ablation to form the plurality of first grooves to provide a second laser used for laser ablation to form the at least one registration feature.

6. The method according to any one of claims 1 to 3, in, For at least one of the plurality of first grooves, laser ablation is performed to form a groove exposing at least a surface of the first electrode layer; and wherein the method comprises: A monomer suspended in an inert gas is provided in the region of the recesses during laser ablation so that the monomer polymerizes onto the exposed surface of the first electrode layer.

7. The method according to any one of claims 1 to 3, in, The method includes moving the stack in a first direction simultaneously or intermittently with laser ablation for forming the plurality of first grooves or the at least one registration feature, and wherein each of the plurality of first grooves formed in the stack is elongated in a direction substantially parallel to the first direction.

8. The method according to any one of claims 1 to 3, in, The plurality of first grooves are formed sequentially, and wherein the registration feature is formed after a given number of sequential first grooves of the plurality of first grooves are formed.

9. The method according to any one of claims 1 to 3, in, The registration features include markings on a surface of the stack, recesses into the stack that are wider and / or deeper and / or have a different shape than each of the plurality of first recesses, or perforations in the stack.

10. An apparatus for processing a stack for an energy storage device, the stack comprising a substrate, a first electrode layer, a second electrode layer and an electrolyte layer between the first electrode layer and the second electrode layer, the apparatus include: A laser system configured to, in use: laser ablating the stack to form a plurality of first grooves in the stack, each of the plurality of first grooves passing through the first electrode layer and the electrolyte layer; and Wherein, the device is configured as follows: forming at least one registration feature in or on the stack that is different from each of the plurality of first recesses, identifying the registration feature; and folding the stack at or toward an identified registration feature, wherein every given number of adjacent first recesses in the plurality of first recesses forms one of the registration features.

11. A stack for an energy storage device, the stack comprising a substrate, a first electrode layer, a second electrode layer, and an electrolyte layer between the first electrode layer and the second electrode layer; the stack defines a plurality of first grooves, each first groove passing through the first electrode layer and the electrolyte layer; the stack also comprises at least one alignment feature different from each of the plurality of first grooves, the at least one alignment feature being arranged to be identified, the stack being folded at or towards the alignment feature, wherein each given number of adjacent first grooves in the plurality of first grooves forms one of the alignment features.

12. The stack according to claim 11, in, Each of the plurality of first recesses has an electrically insulating material deposited therein.

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