Battery Electrode Foil Laser Cutting With Pulsed Heat Control
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Solution Overview
Problem
Laser cutting of metal foils, particularly for battery electrodes, faces challenges such as deformation and tearing due to inappropriate parameter settings, necessitating a method that ensures higher quality and precision.
Innovation Solution
A metal foil laser cutting method involving intermittent laser pulses with specific energy and rise time settings, along with controlled overlapping ratios and spot diameters, to enhance cutting quality and minimize thermal effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If laser cutting parameters are set similarly to those used for thicker metal members, then the laser cutting process can be simplified, but the metal foil easily gets deformed or torn and desired quality cannot be achieved
Solution Approach 1:
The patent applies parameter changes by optimizing specific laser cutting parameters for metal foil: pulse width of 10-100 μs, pulse frequency of 1-10 kHz, duty cycle of 1-10%, and laser power density of 10^4-10^6 W/cm². These parameter adjustments resolve the contradiction by enabling simple process implementation while achieving high cutting quality without deformation or tearing of the metal foil.
2Productivity
If higher energy laser pulses are used to improve cutting speed, then productivity increases, but thermal effects increase causing deformation and tearing of the metal foil
Solution Approach 1:
The patent applies periodic action through pulsed laser irradiation with pulse widths of 10-100 μs and frequencies of 1-10 kHz. This periodic energy delivery enables high productivity by maintaining high peak power for fast cutting, while the intermittent nature allows heat dissipation between pulses, preventing excessive thermal accumulation that causes deformation and tearing.
Solution Approach 2:
The patent uses dynamic control of laser parameters including pulse width (10-100 μs), frequency (1-10 kHz), and duty cycle (1-10%). This dynamic parameter adjustment enables the system to adapt energy delivery to the thermal characteristics of metal foil, achieving high cutting speed while controlling thermal effects through variable pulse characteristics.
3Ease of operation
If continuous laser irradiation is used to simplify the process, then the process is easier to operate, but the metal foil deforms and tears due to excessive heat accumulation
Solution Approach 1:
The patent applies periodic action by using pulsed laser irradiation instead of continuous irradiation. With pulse widths of 10-100 μs and duty cycles of 1-10%, the system maintains operational simplicity through automated pulse control while preventing heat accumulation that would deform or tear the metal foil, thus preserving structural integrity.
4Object-affected harmful factors
If shorter pulse duration is used to reduce thermal effects, then deformation and tearing are reduced, but the energy per pulse decreases requiring more pulses for complete cutting
Solution Approach 1:
The patent uses dynamic parameter optimization with pulse widths of 10-100 μs and frequencies of 1-10 kHz. This dynamic control achieves short enough pulses to minimize thermal effects and deformation, while maintaining high peak power density (10^4-10^6 W/cm²) to ensure each pulse contributes effectively to cutting, reducing the total number of pulses needed.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method achieves high-quality laser cutting of metal foils for battery electrodes by reducing protrusions, burrs, and discoloration, ensuring precise and efficient processing.
Implementation Method 1
emitting the laser light onto a certain part to be cut of the workpiece, so as to melt the part with energy of the laser light
Implementation Method 2
melt the part with energy of the laser light
Implementation Method 3
intermittently irradiating a metal foil that forms an electrode of a battery and that serves as a workpiece with a pulse of a laser light
Data Source
AI summary
A metal foil laser cutting method includes: intermittently irradiating a metal foil that forms an electrode of a battery and that serves as a workpiece with a pulse of a laser light of which energy per pulse is 2 mJ or more and 100 mJ or less and of which rise time is 2 μs or shorter to laser cut the workpiece.